DSTAN 02-878 Issue1 PDF

Ministry of Defence
Defence Standard 02-878

Issue 1 Publication Date 30 June 2011
Non-Ferrous Tubes and Pipes

for use in
HM Submarines and
Surface Ships not in Class
Category 2
DEF STAN 02-878 Issue 1
Contents
Foreword .........................................................................................................................................................vii
0
Introduction.............................................................................................................................................x
Scope.......................................................................................................................................................1
Warning ...................................................................................................................................................1
Normative References ...........................................................................................................................1
Terms and Definitions............................................................................................................................3
5
5.1
5.2
5.3
5.4
5.5
5.6
Design Requirements ............................................................................................................................4

General ...............................................................................................................................................4
Material Selection..............................................................................................................................5
Corrosion of Tube Materials ............................................................................................................7
Other Physical Properties ................................................................................................................9
Joining and Welding .......................................................................................................................10
Tube Wall Thickness.......................................................................................................................10
Information to be Supplied by the Purchaser ...................................................................................13
Tube Manufacture.................................................................................................................................13
8
Test Methods and Examination Requirements .................................................................................14
8.1
Selection of Originating Standards ...............................................................................................14
8.2
Destructive Tests ............................................................................................................................14
8.2.1
Sampling .....................................................................................................................................14
8.2.2
Chemical Analysis .....................................................................................................................14
8.2.3
Tensile Tests ..............................................................................................................................14
8.2.4
Hardness Tests ..........................................................................................................................14
8.2.5
Re-tests .......................................................................................................................................14
8.3
Non-destructive Tests.....................................................................................................................15
8.3.1
Visual Examination ....................................................................................................................15
8.3.2
Dimensional Inspection.............................................................................................................15
8.3.3
Leak Tightness Tests.................................................................................................................15
8.3.3.1
Eddy Current Test .................................................................................................................15
8.3.3.2
Hydrostatic Test ....................................................................................................................15
8.3.3.3
Pneumatic Test (Heat Exchanger Tubes only)...................................................................16
8.3.4
Pressure Proof Test ...................................................................................................................16
8.3.5
Magnetic Permeability ...............................................................................................................16
8.3.6
Ultrasonic Tests .........................................................................................................................16
9
Acceptance Standards.........................................................................................................................16
9.1
9.1.1
9.1.2
Mechanical Properties Tests.....................................................................................................16
9.1.3
Hardness Test ............................................................................................................................16
9.2
9.2.1
Visual Examination ....................................................................................................................17
9.2.2
Dimensional Checks ..................................................................................................................17
9.2.3
Leak Tightness Tests.................................................................................................................17
9.2.3.1
Eddy Current Test .................................................................................................................17
9.2.3.2
Hydrostatic Test ....................................................................................................................17
9.2.3.3
Pneumatic Test (Heat Exchanger Tubes only)...................................................................17
9.2.4
Pressure Proof Test ...................................................................................................................17
9.2.5
Magnetic Permeability ...............................................................................................................17
9.2.6
Ultrasonic Tests .........................................................................................................................17
ii

9.3
9.4
Rejection ..........................................................................................................................................17
Summary of Tube Procurement Process .....................................................................................18
10
Quality Assurance Documentation ....................................................................................................19
10.1
General .............................................................................................................................................19
10.2
Certificate of Conformity ................................................................................................................19
10.3
Records ............................................................................................................................................19
11
Identification .........................................................................................................................................19
Annex A Test Methods Specific to this Defence Standard ........................................................................21

A.1 Scope.....................................................................................................................................................21
A.2 Flattening and Bend Tests for Copper Alloys ...................................................................................21
A.2.1
Flattening Test.................................................................................................................................21
A.2.2
Double Bend Test............................................................................................................................21
A.3 Non-destructive Test Procedures.......................................................................................................21
A.3.1
Eddy Current Test ...........................................................................................................................21
A.3.1.1
Method of Test............................................................................................................................21
A.3.1.2
Calibration ..................................................................................................................................22
A.3.1.3
Checking of Equipment .............................................................................................................22
A.3.2
Ultrasonic Test Method ..................................................................................................................22
A.3.2.1
Method of Test............................................................................................................................22
A.3.2.2
Equipment...................................................................................................................................23
A.3.2.3
Calibration Standards................................................................................................................23
A.3.2.4
Calibration and Checking of Equipment..................................................................................24
A.3.3
Ultrasonic Thickness Gauging ......................................................................................................24
A.3.3.1
Method of Test............................................................................................................................24
A.3.3.2
Calibration Standards................................................................................................................24
A.3.3.3
Calibration and Checking of Equipment..................................................................................24
Annex B Specific Requirements for Copper Tubes (previously covered by Def Stan 02-837) ..............25
B.1 Scope.....................................................................................................................................................25
B.2 Manufacture ..........................................................................................................................................25
B.2.1
Tube production ..............................................................................................................................25
B.2.2
Condition of Tubing ........................................................................................................................25
B.2.3
Supply Requirements .....................................................................................................................25
B.3 Specific Tests .......................................................................................................................................26
B.3.1
B.3.1.1
Mechanical Test Sampling ........................................................................................................26
B.3.1.2
B.3.1.3
Mechanical Tests .......................................................................................................................26
B.3.2
Non-destructive Tests ....................................................................................................................26
B.3.2.1
Samples for Dimensional Checks ............................................................................................26
B.4 Acceptance Criteria..............................................................................................................................27
B.4.1
Chemical Analysis...........................................................................................................................27
B.4.2
Mechanical Tests.............................................................................................................................27
B.4.3
Non-destructive Tests ....................................................................................................................27
B.4.4
Rejection ..........................................................................................................................................27
B.5 Identification .........................................................................................................................................27
Annex C Specific Requirements for 70/30 Copper-nickel Alloy Tubes (previously detailed in Def Stan
02-780 Part 3) ........................................................................................................................................31
C.1 Scope.....................................................................................................................................................31
C.2 Tube Classification ..............................................................................................................................31
C.3 Manufacture ..........................................................................................................................................31
C.3.1
Tube Production..............................................................................................................................31
C.3.2
C.3.3
C.4 Specific Tests .......................................................................................................................................32
C.4.1
C.4.1.1
Sampling for Destructive Tests ................................................................................................32
C.4.1.2
C.4.1.3
iii

C.4.2
C.4.2.1
C.4.2.2
Ultrasonic Wall Thickness Checks...........................................................................................32
C.5 Acceptance Criteria..............................................................................................................................32
C.5.1
C.5.1.1
C.5.1.2
C.5.2
C.5.3
Rejection ..........................................................................................................................................33
C.6 Identification .........................................................................................................................................33
Annex D Specific Requirements for 90/10 Copper-nickel Alloy Tubes (previously covered by Def Stan
02-779 Part 3) ........................................................................................................................................39
D.1 Scope.....................................................................................................................................................39
D.2 Tube Classification ..............................................................................................................................39
D.3 Manufacture ..........................................................................................................................................39
D.3.1
Tube production ..............................................................................................................................39
D.3.2
D.3.3
D.4 Specific Test Methods .........................................................................................................................39
D.4.1
D.4.1.1
D.4.1.2
D.4.1.3
D.4.2
D.4.2.1
D.4.2.2
D.5 Acceptance Criteria..............................................................................................................................40
D.5.1
D.5.1.1
D.5.1.2
D.5.2
D.5.3
Rejection ..........................................................................................................................................41
D.6 Identification .........................................................................................................................................41
Annex E Specific Requirements for Aluminium-nickel-silicon-brass Tubes (previously covered by
Defence Standard 02-749 Part 3) ........................................................................................................44
E.1 Scope.....................................................................................................................................................44
E.2 Tube Classification ..............................................................................................................................44
E.3 Manufacture ..........................................................................................................................................44
E.3.1
Tube Production..............................................................................................................................44
E.3.2
E.3.3
E.4 Specific Tests .......................................................................................................................................44
E.4.1
E.4.1.1
E.4.1.2
E.4.1.3
E.4.2
E.4.2.1
E.4.2.2
E.5 Acceptance Criteria..............................................................................................................................45
E.5.1
E.5.1.1
E.5.1.2
E.5.2
E.5.3
Rejection ..........................................................................................................................................46
E.6 Identification .........................................................................................................................................46
Annex F Advisory Material Property Datasheets ........................................................................................48
iv
Tables
Table 1 Specifications and Room Temperature Mechanical Properties of Possible Ferrous
Materials for Tubes .........................................................................................................................6
Table 2 Specifications and Room Temperature Mechanical Properties of Possible Non-ferrous
Materials for Tubes .........................................................................................................................7
Table 3 Comparative Corrosion Resistance of Tube Materials ................................................................8
Table 4 Comparison of Corrosion Severity for Various Tube Service Environments............................9
Table 5 Guideline Maximum Velocity Limits for Seawater........................................................................9
Table 6 Comparative Costs for Possible Tube Materials ........................................................................10
Table A.1 Ultrasonic Calibration Notch Depths........................................................................................23
Table B.1 Metric Tube for Fresh Water, Oil and LP Air Systems for use at Working Pressures
up to 6 bar and Temperatures up to 75C...................................................................................28
Table B.2 Imperial Tube for: (a) Steam Systems at Working Pressures up to 10.5 bar and
Temperatures up to 187C and (b) General use up to 12 bar and Temperatures up to
175C ..............................................................................................................................................28
Table B.3 Imperial Tube for: (a) Steam Systems at Working Pressures up to 17 bar and
Temperatures up to 208C and (b) General use at Working Pressures up to 25 bar and
Temperatures up to 190C............................................................................................................29
Table B.4 Imperial Tube for: (a) Pressure Gauge Piping for use at Working Pressures up to 83
bar and Temperatures up to 75C and (b) Steam Systems at Working Pressures up to
17 bar and Temperatures up to 208C ........................................................................................29
Table B.5 Metric Tube for Refrigeration Systems at Working Pressures up to 11 bar and
Temperatures to 75C ...................................................................................................................29
Table B.6 Imperial Tube for Refrigeration Systems at Working Pressures up to 11 bar and
Temperatures up to 75C..............................................................................................................30
Table C.1 Classification of Tubes ..............................................................................................................33
Table C.2 70/30 Copper-nickel Alloy Tubes - General Purpose (metric) ...............................................34
Table C.3 70/30 Copper-nickel Alloy Tubes. General Purpose (imperial): Dimensions,
classification and working pressures.........................................................................................35
Table C.4 Chemical Composition...............................................................................................................36
Table C.5 Room Temperature Mechanical Properties .............................................................................36
Table C.6 Tolerances for General Purpose Tubes ...................................................................................37
Table C.7 Tolerances for Condenser and Heat Exchanger Tubes .........................................................38
Table D.1 Class 1-175 Imperial Tubes (working pressure 175 psi) ........................................................41
Table D.2 Data for Class 1-10 Metric Tubes (working pressure 10 bar).................................................42
Table D.3 Data for Class 1-16 Metric Tubes (working pressure 16 bar).................................................43
Table D.4 Specified Annealed 90/10 Copper-nickel Room Temperature Mechanical Properties .......43
Table E.1 Tube Sizes and Working Pressures. (* Non-preferred sizes).................................................46
Table E.2 Specified Al-Ni-Si-Brass Room Temperature Mechanical Properties...................................46
Table E.3 Permitted Tube Dimensional Tolerances .................................................................................47
Table F.1 Copper-phosphorus Deoxidised Non-arsenical ......................................................................49
Table F.2 70/30 Copper-nickel ....................................................................................................................51
Table F.3 90/10 Copper-nickel ....................................................................................................................53
Table F.4 Aluminium-nickel-silicon-brass ................................................................................................55
v

Table F.5 Carbon, Carbon-manganese and Chromium-molybdenum Steels........................................57
Table F.6 18% Chromium 10% Nickel Austenitic Stainless Steel...........................................................59
Table F.7 18% Chromium 10% Nickel Titanium Austenitic Stainless Steel...........................................61
Table F.8 18% Chromium 10% Nickel Niobium Austenitic Stainless Steel ...........................................63
Table F.9 18% Chromium 12% Nickel 2% Molybdenum Austenitic Stainless Steel .............................65
Table F.10 20% Chromium 18% Nickel 6% Molybdenum Super Austenitic Stainless Steel ................67
Table F.11 22% Chromium 5% Nickel 3% Molybdenum Duplex Stainless Steel...................................69
Table F.12 25% Chromium 7% Nickel 3.5% Molybdenum Tungsten Super Duplex Stainless
Steel................................................................................................................................................71
Table F.13 Nickel-chromium-molybdenum-niobium Alloy 625 ...............................................................73
Table F.14 Nickel-copper Alloy 400 ...........................................................................................................75
Table F.15 Titanium Alloy, Commercial Purity .........................................................................................77
Table F.16 Aluminium-magnesium-manganese Alloy .............................................................................79
Table F.17 Aluminium-2% magnesium alloy.............................................................................................81
vi
Foreword
AMENDMENT RECORD
Amd No
Date
Text Affected
Signature and Date
REVISION NOTE
A new policy of having performance based standards for non-ferrous tubes and pipes replacing prescriptive
standards was agreed in the Defence Standards rationalization plan in the Sea Systems Group of the MOD.
Def Stan 02-878 is a new standard which has been produced to implement this new policy, and supersedes
the Defence Standards listed below.
HISTORICAL RECORD
This standard supersedes the following:
Defence Standard 02-749 Part 3 Issue 1
Defence Standard 02-837 Issue 2
Defence Standard 07-259 Issue 1
NES 749 Part 3 Issue 2
NES 837 Issue 2
DGS 233A
DGS 271B
DGS 312B
DGS 8556D
DGS 8557C
DGS 8558B
DGS 8559D
DGS 856B
DGS 8562F
AD Spec 1011
EinC 3T103
EinC 4T104
DNC C7
DNC C9
Apr 2000
Apr 2000
Apr 2000
Apr 2000
Oct 2005
Apr 2000
May 1987
Dec 1998
Aug 1998
Mar 1989
Dec 1998
Oct 1971
Jul 1974
Apr 1976
Apr 1976
Sep 1963
Jun 1963
Mar 1963
Nov 1963
Jul 1967
Apr 1958
Jun 1955
vii

Sponsorship
1.
This Defence Standard (Def Stan) is sponsored by the Sea Systems Group, Defence Equipment and
Support, Ministry of Defence (MOD).
2.
The complete Defence Standard 02-878 Issue 1 comprises:

Metallic tubes and pipes for fluid handling in HM Surface Ships and Submarines not in Class
3.
If it is found to be unsuitable for any particular requirement the MOD is to be informed in writing of the
circumstances.
4.
Any user of this Defence Standard either within MOD or in industry may propose an amendment to it.
Proposals for amendments that are not directly applicable to a particular contract are to be made to the
publishing authority DStan and those directly applicable to a particular contract are to be dealt with using
contract procedures.
5.
No alteration is to be made to this Defence Standard except by the issue of an authorised
amendment.
6.
Unless otherwise stated, reference in this Defence Standard to approval, approved, authorised or
similar terms, means the MOD in writing.
7.
Any significant amendments that may be made to this Defence Standard at a later date will be
indicated by a vertical sideline. Deletions will be indicated by 000 appearing at the end of the line interval.
8.
Extracts from British Standards within this Defence Standard have been included with the permission
of the British Standards Institution.
Conditions of Release
General
9.
This Defence Standard has been devised solely for the use of the MOD, and its contractors in the
execution of contracts for the MOD. To the extent permitted by law, the Crown hereby excludes all liability
whatsoever and howsoever arising (including but without limitation, liability resulting from negligence) for any
loss or damage however caused when the Defence Standard is used for any other purpose.
10. This document is Crown Copyright and the information herein may be subject to Crown or third party
rights. It is not to be released, reproduced or published without written permission of the MOD.
11. The Crown reserves the right to amend or modify the contents of this Defence Standard without
consulting or informing any holder.
MOD Tender or Contract Process
12. This Defence Standard is the property of the Crown. Unless otherwise authorized in writing by the
MOD, it must be returned on completion of the contract, or submission of the tender, in connection with
which it is issued.
13. When this Defence Standard is used in connection with a MOD tender or contract, the user is to
ensure that he is in possession of the appropriate version of each document, including related documents,
relevant to each particular tender or contract. Enquiries in this connection may be made of the Authority
named in the tender or contract.
14. When Defence Standards are incorporated into MOD contracts, users are responsible for their correct
application and for complying with contractual and other statutory requirements. Compliance with a Defence
Standard does not of itself confer immunity from legal obligations.
viii

Categories of Naval Defence Standard
15.
The Category of this Maritime Defence Standard has been determined using the following criteria:
a)
Category 1. If not applied, may have a Critical effect on the following:

Safety of the vessel, its complement or third parties.
Operational performance of the vessel, its systems or equipment.
b)
Category 2. If not applied, may have a Significant effect on the following:

Safety of the vessel, its complement or third parties.
Operational performance of the vessel, its systems or equipment.
Through-life costs and support.
c)
Category 3. If not applied, may have a Minor effect on the following:

MOD best practice and fleet commonality.
Corporate experience and knowledge.
Current support practice.
Related Documents
16.
In the tender and acquisition processes the related documents in clause 3 can be obtained as follows:
a)
British Standards
British Standards Institution,

389 Chiswick High Road,
London,
W4 4AL
b)
Defence Standards
Defence Equipment and Support

UK Defence Standardization,
Kentigern House
65 Brown Street,
Glasgow,
G2 8EX
c)
Other documents
Tender or Contract Sponsor to advise.
17. All applications to Ministry Establishments for related documents are to quote the relevant MOD
Invitation to Tender or Contract Number and date, together with the sponsoring Directorate and the Tender
or Contract Sponsor.
18. Prime Contractors are responsible for supplying their sub-contractors with relevant documentation,
including specifications, standards and drawings.
Health and Safety
Warning
19. This Defence Standard may call for the use of processes, substances and procedures that may be
injurious to health if adequate precautions are not taken. It refers only to technical suitability and in no way
absolves either the supplier or any user from statutory obligations relating to health and safety at any stage
of manufacture or use. Where attention is drawn to hazards, the list of those quoted may not necessarily be
exhaustive.
20. This Defence Standard has been written and is to be used taking into account the policy stipulated in
JSP430: MOD Ship Safety Management System Handbook.
Additional Information
(There is no relevant information)
ix
Introduction
0.1 The Royal Navy has gained considerable experience in the use of pipework for the transport of liquids
and gases within HM Surface Ships and Submarines over many years. It is on the basis of this corporate
knowledge that the Admiralty Pipework Standards (BR 3013) and the various system design Defence
Standards have evolved to their current status. The text of this particular Standard has also drawn on this
body of knowledge when citing general requirements, material selection, material corrosion performance,
etc.
0.2 A formal selection method for tube materials and sizes as part of a design process has been defined
in this Defence Standard, permitting the use of materials to commercial standards not previously codified by
Defence Standards or the preceding Naval Engineering Standards. This process includes defining the tube
non-destructive test requirements necessary to ensure the desired performance and component quality
assurance for naval applications.
0.3 Previous Defence Standards and Naval Engineering Standards have compiled standard tube
geometries used in Royal Navy vessels. To ensure like-for-like replacement of parts on vessels built to
these earlier Standards, the necessary test requirements and dimensions from these earlier Standards have
been included in this Defence Standard as a series of Annexes.
0.4 Where previous Defence Standards for tubes, such as Def Stan 02-831 covering aluminium alloy
tubes, have been found not to contain performance critical requirements or important component sizing data,
these standards have not been included as Annexes of this Defence Standard. Any naval requirement for
aluminium tubes for fluid or gas applications can be addressed using the general test methods and
acceptance criterion stated in clauses 13 and 14 of this Standard.
0.5 Previous naval experience, as embodied by the various material Annexes, has found the following
tube material / service combinations effective:
a)
90/10 and 70/30 copper-nickels for general seawater supply piping. The 70/30 copper-nickel alloy
offers somewhat greater strength, being particularly used for higher pressure components in HM
Submarines, but at a greater price than 90/10 copper-nickel. Both copper-nickel alloys show very high
resistance to stress corrosion cracking in seawater service.
b)
Seawater cooler heat exchanger tubing has traditionally used 70/30 copper-nickel tube. This material
provides some anti-fouling effects to limit macro-fouling of tubes, and has the best erosion-corrosion
resistance of the copper alloys commonly used in naval tubing.
c)
Aluminium-nickel-silicon-brass has provided a low magnetic permeability, higher strength and lower
price alternative to 70/30 copper-nickel for high pressure air and hydraulic pipework.
d)
Titanium tubing has proved corrosion resistant in seawater heat exchanger applications, with greater
erosion-corrosion resistance than the copper-nickel alloys. The increased material cost may be offset
in part against the use of thinner tubes, based on the minimal corrosion rate of the titanium and its
greater strength.
0.6 Industrial experience, especially in offshore oil and gas applications, has also indicated some effective
tube material / service combinations:
a)
Super duplex and super austenitic stainless steels have both been used for tubular products with
seawater up to 40C.
b)
Titanium tubes are being adopted for oil rig fire main systems, to avoid previous corrosion problems
with mild steel and copper-nickel materials.

c)
Nickel-chromium-molybdenum alloys such as Alloy 625 can show high resistance to pitting and
crevice corrosion in seawater at elevated temperatures.
0.7 Some examples of the necessity to carefully select the material and tube size for a particular system
are given for illustrative purposes:
a)
Submarine steam drains were for many years manufactured from mild steel. However these were
particularly susceptible to corrosion in this wet steam environment. This necessitated frequent
replacement and the resulting costs and non-availability of the platform. The selection of a more
corrosion resistant alloy (nickel-chromium-molybdenum Alloy 625) removed the need for repeated
replacement, reducing maintenance costs and increasing platform availability.
b)
Erosion-corrosion due to excessive seawater flow velocities has caused failure of copper-nickel tubes.
These alloys are also susceptible to sulphide polluted waters and Microbial Influenced Corrosion
(MIC) during the initial period after installation. Def Stan 02-781 has been revised in Issue 2 to
improve the corrosion performance of such copper-nickel tubes.
c)
An additional restriction on the iron content of 90/10 copper-nickel to between 1.5 and 2.0% has been
proposed to improve the seawater erosion-corrosion resistance of the alloy (see clause D.5.1.1).
d)
Aluminium-nickel-silicon-brass can become susceptible to stress corrosion cracking if excessively cold

worked or over-heated, leading to over-aging of the alloy.
e)
Non-copper based alloy tubes handling seawater can become rapidly clogged by marine organism
growths if not cleaned or treated by biocides / antifoulants such as chlorine.
f)
Heat exchanger tubes can suffer corrosion accelerated fatigue due to flow induced tube vibration if of
insufficient rigidity.
g)
The poor thermal conductivity of titanium compared to copper-nickel heat exchanger tubes can be
compensated for by the use of thinner tubes, utilising the greater corrosion and erosion-corrosion
resistance of titanium.
xi
Blank Page
xii
Non-Ferrous Tubes and Pipes for use in HM Submarines and

Surface Ships not in Class
1
Scope
This Standard is to advise and inform the selection of tubes and pipes for the transport of liquids and gases
within HM Submarines and Surface Ships not in Class. It specifies the requirements, inspection and testing
for non-ferrous tubes and pipes. The Standard replaces five specific alloy Standards (Def Stans 02-749
Part 3, 02-779 Part 3, 02-780 Part 3, 02-831 Part 3 and 02-837) but retains the procurement aspects of
these documents in appropriate Annexes. Def Stan 02-831 covering aluminium alloy tubes, has been found
not to contain performance critical requirements or important component sizing data and so these Standards
have been superseded by this Defence Standard, but not replaced by separate Annexes of this Defence
Standard. Requirements for the procurement of steel tubes and pipes are specified in Def Stan 02-864. Def
Stan 02-878 only applies to non-nuclear systems.
Warning
The Ministry of Defence (MOD), like its contractors, is subject to both United Kingdom and European laws
regarding Health and Safety at Work. Many Defence Standards set out processes and procedures that
could be injurious to health if adequate precautions are not taken. Adherence to those processes and
procedures in no way absolves users from complying with legal requirements relating to Health and Safety at
Work.
Normative References
3.1 The publications shown below are referred to in the text of this Standard. Publications are grouped
and listed in alpha-numeric order.
ASME B31
Code for pressure piping
ASTM A269
Seamless and welded austenitic stainless steels tubing for general service
ASTM A789
Seamless and welded ferritic / austenitic (duplex) stainless steel tubing for general
service
ASTM B165
Nickel-copper alloy (UNS N04400) seamless pipe and tube
ASTM B338
Seamless and welded titanium and titanium alloy tubes for condensers and heat
exchangers
ASTM B444
Nickel-chromium-molybdenum-columbium alloys (UNS N06625) and nickel-chromiummolybdenum-silicon alloy (UNS N06219) pipe and tube
ASTM G36
Evaluation stress-corrosion-cracking resistance of metals and alloys in a boiling

magnesium chloride solution
ASTM G38
Practice for making and using C-ring stress-corrosion test specimens
BR 1326
Regulations for atmosphere control in submarines
BR 3008
Materials and processes (Mechanical Engineering).

Chapter 1
Metals

BR 3013 (1) and (2)
Admiralty pipework standards: Imperial and metric
BR 3021 (2)
Shock manual
BR 8470
Shock and vibration manual
BS 3074
Nickel and nickel alloys: seamless tube
BS EN 755-2
Aluminium and aluminium alloys - Extruded rod / bar, tube and profiles
Part 2 Mechanical properties
BS EN 10216
Seamless steel tubes for pressure purposes. Technical delivery conditions

Part 1 Non-alloy steel tubes with specified room temperature properties
Part 2 Non-alloy and alloy steel tubes with specified elevated temperature
properties
Part 5 Stainless steel tubes
BS EN 12449
Copper and copper alloys- seamless, round tubes for general purposes
BS EN 12451
Copper and copper alloys- seamless, round tubes for heat exchangers
BS EN 13445-1
Unfired pressure vessels

Part 1 General
BS EN 13480-3
Metallic industrial piping

Part 3 Design and calculation
BS EN ISO 6507-1
Metallic materials - Vickers hardness test

Part 1 Test method
BS EN ISO 6892-1
Metallic materials. Tensile testing

Part 1 Method of test at ambient temperature
BS MA 18
Salt water piping systems in ships
Def Stan 02-329
Requirements for heat exchangers for HM Surface Ships and Submarines
Def Stan 02-719
Sea Water Systems for H M Surface Ships
Def Stan 02-729
Requirements for non-destructive examination methods

Part 3 Eddy Current
Part 5 Ultrasonics
Def Stan 02-772
Welding and fabrication of pipework, machinery and engineering components for HM

Submarines and Surface Ships not in Class
Def Stan 02-781
Protection of Seawater System Pipework and Heat Exchanger Tubes in HM Surface

Ships and Submarines
Def Stan 02-797
Pipework Engineering
Part 1 General
Def Stan 02-864
Carbon, Carbon-Manganese, and Chromium-Molybdenum Steel Pipes and Tubes for

Pressure Purposes
Def Stan 07-247
The selection of materials on the basis of their fire characteristics

Part 1 The selection of materials on the basis of their fire characteristics
Def Stan 08-120
Requirements for determining the shock strength of equipment (Restricted)

MAP 01-109
Metals and corrosion guide
JSP 430
Ship Safety Managements System Handbook
SSP 25
Quality Assurance for Safety in Submarines (Restricted)
3.2 Reference in this Standard to any normative references means in any Invitation to Tender or contract
the edition and all amendments current at the date of such tender or contract unless a specific edition is
indicated. For some standards the most recent editions shall always apply due to safety and regulatory
requirements. Examples of these are Flight Order AvP 67 and Statutory Instruments (SIs)
3.3 In consideration of clause 3.2 above, users shall be fully aware of the issue, amendment status and
application of all normative references, particularly when forming part of an Invitation to Tender or contract.
Responsibility for the correct application of standards rests with users.
3.4 DStan can advise regarding where to obtain normative referenced documents. Requests for such
information can be made to the DStan Helpdesk. Details of how to contact the helpdesk are shown on the
outside rear cover of Defence Standards.
Definitions
For the purpose of this standard the following definitions apply.

4.1
Acceptance Authority
This is as specified in the tender, contract document or order. Where this is not known, enquiries are to be
directed to MOD.
4.2
Annealed
Fully softened material, achieved by heating to a suitable temperature and holding at that temperature for a
time which is dependent on the thickness of the tube wall.
4.3
Batch
A number of tubes, maximum 300, of the same nominal dimensions manufactured from the same cast by the
same process and heat treated to the same standard in the same furnace at the same time.
4.4
Billet
A mass of metal produced from a single cast intended for further processing.
4.5
Cast
A cast is:
a)
the product of one furnace melt, or
b)
the product of one crucible melt, or
c)
the product of a number of furnace or crucible melts where such are aggregated prior to sampling, or
d)
in continuous casting 2000 kg or fraction thereof of metal poured.
4.6
Contractor
The Firm, Company, Organisation or Establishment working within the scope of this Defence Standard.
4.7
Design Authority
The approved firm, MOD establishment or branch responsible for the detailed design of materiel to approved
specifications and authorized to sign a certificate of design or certify sealed drawings.

4.8
Design Pressure
The maximum designed operating pressure of a tube system. Previously termed the Working Pressure in
Naval Engineering Standards.
4.9
First Level
Safety critical components and systems, as defined in SSP 25.
4.10
Originating Standard
A recognised standard used to define tubes by material and / or tube size, falling under the additional
requirements of this Defence Standard.
4.11
Ovality
The ratio of maximum external to minimum external diameter of the tube.
4.12
Pipe
For the purposes of this Defence Standard, pipe and tube are equivalent terms. Tube is used in preference
throughout this Defence Standard.
4.13
Tube
A hollow product of uniform wall thickness, produced from billet by hot extrusion, piercing or pilgering
followed by cold reduction and / or cold drawing processes.
Design Requirements
5.1
General
a)
The form and material selection of tubes under this Standard shall be sufficient to meet the following
requirements, imposed by the design intent of the system for which the tubes are being selected:
1)
NOTE
Resistance to maximum Design Pressure, at maximum and minimum operating temperature.

Minimum temperature for refrigerant systems and compressed gas systems undergoing rapid depressurisation may be below ambient air temperature.
2)
Strength to sustain external loading (including self mass of pipework and contained fluids).
3)
Tolerance of cyclic loading and resistance to fatigue cracking, as appropriate.
4)
Resistance to deleterious corrosion and related deterioration from contained fluid or gas (i.e.
internal environment).
5)
Resistance to deleterious corrosion and related deterioration from installation environment (i.e.
external environment).
6)
Tolerance of excursion operating or environmental conditions.
7)
Affordability.
8)
Compatibility with pipe system fabrication and joining processes.
9)
Fire resistance / shock resistance, if required.

10)
b)
Special functional properties (e.g. antifouling, thermal conductivity, non-magnetic etc), if

required.
These requirements for a particular system determine the following properties:

1)
Sizing of tubes (wall thickness and internal diameter).
2)
Minimum mechanical properties of the selected tube material, including hardness.
3)
Corrosion resistance of tube material to the appropriate chemical/environments, including

velocity related erosion and erosion-corrosion.
4)
Methods of tube material fabrication and joining.
5)
Acceptable tube material cost.
c)
The sequence of design and selection choices for tubes is shown schematically in Figure 1.
d)
Additional guidance on pipework design is given in Def Stan 02-719 and 02-797 Part 1.
5.2
Material Selection
a)
Materials for tubes shall be selected based on the intended equipment operating requirements, as
detailed in clause 5.1. Transient conditions must be considered, such as operating condition upsets
and installation or testing processes and procedures.
b)
Specified mechanical properties of materials previously employed for Royal Navy tube applications
and likely alternatives are listed as material data sheets in Annex F and compared in Tables 1 and 2.
c)
Materials shall be selected to meet the system requirements of clause 5.1 from materials of defined
composition and mechanical properties as described by recognised national or international
standards. Preferred sources are: Euronorm Standards (EN), British Standards (BS), American
Society for Testing and Materials (ASTM) and the attached Annexes of this Standard for those
materials previously specified for naval purposes in Naval Engineering Standards (NES) and their
relevant replacement 02-series Defence Standards.
d)
Tube materials shall be identified as complying either with:

1)
A stated commercial Originating Standard, or
2)
Annexes B to E of this Defence Standard, detailing the requirements of the replaced Defence
Standards.
e)
To ensure a tolerance of deformation for tubes materials and based on the requirements of BS EN
13480-3, the elongation to failure for ferrous and non-ferrous materials (excluding aluminium alloy) for
tubes must be >16% (longitudinal, at the design tube wall thickness and at the minimum tube
operating temperature).
f)
Elongation to failure for aluminium alloys must be >14% (longitudinal, at the design tube wall thickness
and at the minimum tube operating temperature) for tubes subject to cold forming, or >10% for tubes
not subject to cold forming.

Table 1 Specifications and Room Temperature Mechanical Properties
of Possible Ferrous Materials for Tubes
Minimum 0.2%
Proof or Yield
Stress (MPa)
Tensile
Strength
(MPa)
Minimum
Elongation
(%)
Hardness
(HV)
BS EN 10216-1/2
P235GH (1.0345)
P265GH (1.0425)
20MnNb6 (1.0471)
13CrMo4-5 (1.7335)
235
265
355
290
360-500
410-570
500-650
440-590
25
23
22
22
BS EN 10216-5
X5CrNi18-10 (1.4301)
X2CrNiMo17-12-2 (1.4404)
195
190
500-700
490-690
40
40
ASTM A269 316L annealed
170
>485
40
<220
300
650-850
35
550
800-1000
20
Material
Specification
Carbon / low
alloy steel
Austenitic
stainless steel
Super austenitic
stainless steel
(PREN>40)
Super duplex
stainless steel
(PREN>40)
Note
BS EN 10216-5
X1CrNiMoCuN20-18-7 (1.4547)
ASTM A269 UNS: S31254
BS EN 10216-5
X2CrNiMoCuWN 25-7-4 (1.4501)
Alternative ASTM material may be used, see Def Stan 02-864.
g)
Tube materials shall comply with the requirements of Def Stan 07-247 Part 1 and BR 1326, as
applicable.
h)
For severe corrosive service, such as seawater piping or heat exchangers, some materials must be
excluded based on insufficient corrosion resistance. The following materials shall not be used for
seawater service tubes under this Standard without special additional corrosion prevention measures
approved by the Acceptance Authority:
1)
Carbon or low alloy steels (including galvanised steel).
2)
Brasses (copper-zinc based alloys) with less than 75% copper content.
3)
Stainless steels or nickel-chromium alloys with a Pitting Resistance Equivalent Number (PREN)
of less than 40.
4)
Stress corrosion cracking susceptible austenitic stainless steels at temperatures above 60C.
NOTE
i)
PREN = %chromium + (3.3 x %molybdenum) + (16 x %nitrogen), where %element is the minimum
content of stainless steel or nickel-chromium alloy in the specification.
For exposure to marine atmospheres, the following materials shall not be used due to risk of stress
corrosion cracking:
1)
Brasses (copper-zinc based alloys) with less than 75% copper content.
2)
Susceptible austenitic stainless steels at temperatures above 60C.

j)
Stress corrosion cracking susceptibility is defined as an inability to resist ASTM G36 test conditions for
1000 hours when C-ring samples (to ASTM G38) of the tube are loaded to 90% of material minimum
specified proof stress.
Table 2 Specifications and Room Temperature Mechanical Properties
of Possible Non-ferrous Materials for Tubes
Material
Specification
0.2% Proof
stress (MPa)
Tensile Strength
(MPa)
Minimum
Elongation
(%)
Hardness
(HV)
Pure copper
BS EN 12449 Cu-DHP CW024A
>110
>200
40
40-65
>140
>400
35
<110
>120
>370
35
85-120
>110
>310
35
<95
>90
>290
30
75-110
>230
>450
40
125-140
>220
>430
40
120-140
>415
>830
30
>275
>690
30
>195
>480
35
NES 310 (Obsolete)
270-400
400-530
25
ASTM B338 Grade 1

ASTM B338 Grade 2
BS EN 755-2, AlMg4.5Mn0.7 AW5083, annealed condition
BS EN 755-2, AlMg2
AW-5251, extruded condition
170-310
275-450
>240
>345
24
20
>125
>270
10
>60
>160
14
70/30 Coppernickel
90/10 Coppernickel
Aluminiumnickel silicon
brass
Ni-Cr-Mo Alloy
625
Nickel-copper
CP (commercial
purity) titanium
Aluminium 5083
Aluminium 5251
Def Stan 02-878 Annex C

Annealed (class 2-4, 6, 7 and 9)
BS EN 12449 CuNi30Mn1Fe,
CW354H annealed
Def Stan 02-878 Annex D
Annealed
BS EN 12449 CuNi10Fe1Mn,
CW352H annealed
Def Stan 02-878 Annex E
BS EN 12449 CuZn13Al1Ni1Si1
CW700R R430/H120 condition
BS 3074 NA21 cold worked and
annealed
annealed
solution treated
5.3
Corrosion of Tube Materials
a)
Weakening of tube materials by general corrosion and local corrosion (pitting), reductions in wall
thickness by erosion-corrosion, stress corrosion cracking or corrosion fatigue from internal and
external environments shall be considered.
b)
Reduction in effective tube wall thickness through-life due to corrosion must be considered in
specifying tube wall thickness, with the possible addition of a corrosion allowance thickness above the
minimum pressure determined wall thickness. Any such corrosion allowance must be determined by
the specific corrosive conditions and the design life of the system.
c)
The galvanic (dissimilar metals) corrosion interactions of tube materials with other pipe system
component materials shall be considered in estimating the corrosion implications of a given material
selection.
d)
Guidelines on tube material corrosion susceptibilities and corrosion rates are detailed in Annex F,
BR 3008 and MAP 01-109. Tables 3 and 4 provide comparative advisory listings of material corrosion
resistance and corrosion severity for various tube applications.

e)
Corrosion allowances may not be required for low severity conditions. Corrosion resistant materials or
protective coatings can be specified to reduce or avoid the requirement for wall thickness corrosion
allowances. The durability of any such coatings must also be considered.
f)
Water velocity limits apply for some materials. Excessive velocity can result in rapid loss of wall
thickness for certain materials due to erosion-corrosion. Suggested maximum permissible seawater
velocities for different tube materials are listed in Table 5.
g)
Seawater velocity should always be at least 1m/s to prevent the settlement of surface deposits and
possible localised corrosion.
Table 3 Comparative Corrosion Resistance of Tube Materials
Material
Corrosion resistance
Notes
Carbon / low alloy steel
Poor in aqueous fluids and

moist atmospheres without
coatings or other measures
Aluminium alloys
Moderate to poor resistance to

seawater, good to moderate in
freshwater and atmosphere
Corrosion resistance varies with alloy composition.

Vulnerable to galvanic corrosion when coupled with
most other metals. Can suffer stress corrosion
cracking
Copper
Moderate in seawater, good in

freshwater
Vulnerable to erosion-corrosion in seawater
Brasses
Moderate in seawater and

some atmospheres, good in
freshwater
Copper-nickel alloys
Good
Nickel-copper alloys
Good
Stainless steels and Nickelchromium-molybdenum

alloys
Very good, except for localised

corrosion in seawater
Titanium alloys
Very good
Vulnerable to erosion-corrosion.
Vulnerable to galvanic corrosion
High zinc brasses at risk of dezincification in

corrosive waters. Limits on acceptable seawater
velocity. Can suffer stress corrosion cracking in
waters or marine atmosphere
Vulnerable to sulphide contamination, limits on
acceptable seawater velocity
Can suffer pitting in stagnant seawater if not coupled
to less noble alloys
Alloys with PREN<40 are at risk of rapid crevice
corrosion and pitting in low temperature seawater. If
PREN>40, high resistance to pitting and crevice
corrosion in seawater at moderate temperatures.
Possible stress corrosion cracking above 60C
Very resistant to seawater and aqueous fluids

Table 4 Comparison of Corrosion Severity for Various Tube Service Environments
Service environment
Corrosion severity
Seawater
Open circuit (oxygenated) boiler feed
High
External maritime atmospheric conditions

Compressed air
Freshwater
Fuel oil / diesel
Medium
Saturated steam
Un-conditioned internal atmospheric conditions
Hydraulic oil
Lubricating oil
Low
Refrigerants
Superheated steam
Closed circuit (deaerated / inhibited) boiler feed
Table 5 Guideline Maximum Velocity Limits for Seawater

Material
Velocity limits (m/s)
Aluminium brass
3.0
90/10 copper-nickel
3.5
70/30 copper-nickel
4.0
Stainless steels / nickel-based alloys /

titanium alloys
>5.0-10.0
NOTE
These maximum velocities are for sea water system pipework of internal
diameter of 100mm or greater, and for heat exchanger tubing. Maximum
velocity limits for seawater system pipework less than 100mm or where
hydrodynamic conditions in heat exchanger tubes are less than ideal should be
reduced. Def Stan 02-719 Def Stan 02-781 Issue 2 Annex B and BS MA 18
provide additional guidance.
5.4
Other Physical Properties
a)
The following properties may be required when selecting materials for tubes:
b)
1)
Resistance to fatigue and corrosion-fatigue where cyclic loading / vibration is significant.
2)
Thermal conductivity, for heat exchanger tubes.
3)
Antifouling properties of copper-alloy tubes in untreated seawater.
4)
Magnetic permeability, where low ferromagnetic signature is required.
5)
Shock resistance, if required, according to Def Stan 08-120, BR 3021 (2) and BR 8470.
Advisory values for some of these properties are detailed in Annex F.

c)
Indications of relative material price (approximate at date of publication) compared to mild steel are
listed in Table 6.
Table 6 Comparative Costs for Possible Tube Materials
d)
Material
Relative cost, per unit

mass
Relative cost, per unit

strength
Mild steel / low alloy steel
x1-2
x1
5000 and 6000 series

aluminium alloys
x10
x6
Low PREN stainless steels
x6
x7
Pure copper
x5
x9
Copper-nickel alloys
x8-15
x15-20
High PREN stainless steels
x10-20
x5-15
Ni-Cr-Mo alloys
x25-30
x12-18
Titanium alloys
x25-30
x12-15
Cost comparisons for complete tube applications must take into account that:
1)
Typically, the through life costs of tubes that require periodic replacement due to corrosion
exceeds those of initially more expensive materials that do not require tube replacement.
2)
The lower density of titanium and aluminium alloy reduces the effective cost per component.
3)
Higher strengths and corrosion resistances may permit economic use of more expensive
materials through reduced tube wall thicknesses.
5.5
Joining and Welding
a)
The joining and weldability of tubes shall be evaluated in selecting tube materials. Mixed metal joints
should be avoided wherever possible.
b)
Requirements for compatibility with mechanical couplings and expansion into heat exchanger tube
plates may place limits on acceptable tube hardness.
c)
Welding shall be in accordance with Def Stan 02-772 unless otherwise agreed by the Design
Authority.
5.6
Tube Wall Thickness
a)
The tensile strength properties of the tube material and the maximum design pressure shall be used to
calculate the minimum tube wall thickness following the procedures of a recognised pipe design code
or pressure vessel design standard. Examples of such standards are BS EN 13445-1, BS EN 134803 and ASME B31.
b)
The final tube wall thickness shall be the next highest wall thickness found in commonly commercially
available tube size which is greater than the sum of the minimum wall thickness (from clause 5.6a)
and any allowance for corrosion or other factor.
c)
Sizes of tube defined in BR 3013 and the previous Defence Standards now superseded in Annexes B
to E of this Standard shall also be acceptable without detailed design calculation, if fully compliant with
the specific stated material requirements and operating system limitations of these Annexes.
10

d)
Tube wall thicknesses shall be sufficient to ensure resistance to buckling and ease of tube expansion,
joining by welding or metallic compression couplings, as appropriate.
e)
If bending of tubes is desired, a bending allowance thickness should be added to the minimum wall
thickness, calculated as follows:
B=
D
t
2.5r
Where:
B is bending allowance.
D is tube outside diameter.
r is centreline radius of bend.
t is tube wall thickness.
11
Define system operating

requirements (Clause 5.1)
Eliminate materials with

inadequate strength or
unsuitable for service
temperature (Clause 5.2)
Eliminate materials
unsuitable for corrosion risk
(Clauses 5.2 and 5.3)
Consider any special properties

required (magnetic/ antifouling /
thermal etc.)? (Clause 5.4)
Consider tube joining

requirements (Clause 5.5)
Select material with

required properties
Select Originating
Standard (Clause 5.2d))
for material
Choose tube size and weight

based on material properties
(Clause 5.6)
Procure and inspect

to selected
(Clauses 8 & 9)
Acceptable
tube cost?
(Clause 5.4)
NO
YES
Figure 1 Schematic Flowchart for Tube Material Selection Process
12
Information to be Supplied by the Purchaser
a)
The following information shall be supplied by the purchaser:

1)
The number of this Defence Standard.
2)
Quantity (mass, total length and / or number of tubes).
3)
Tube dimensions (outside diameter and wall thickness).
4)
Tube material specification, as defined in an Annex of this Standard or another Originating

Standard.
5)
The design pressure of the application for which the tubes are intended.
6)
Any optional / additional testing required according to this Standard or related documents.
Tube Manufacture
a)
The method of tube manufacture shall avoid local material inhomogeneity that adversely affects the
required mechanical or corrosion properties.
b)
Tubes for pressure systems (steam, boiler, compressed air and hydraulic systems etc), or containment
of corrosive fluids, such as seawater, shall be seamless.
c)
Billets or hollows shall be released for production of tubes only when a certificate of conformity or an
analysis shows that they meet the specified requirement.
d)
Tubes are not to be redrawn from used tubing.
e)
All heat treatment is to be carried out in a furnace operating with an atmosphere sulphur content less
than 0.005g/m3.
f)
Surface defects may be removed by grinding, machining or filing with a clean file, provided that the
material thickness does not go below the allowable tolerance. Dressed areas are to be faired
smoothly into the surrounding material and the bottom radius of the dressed area is to be at least
three times the depth of the defect. Surface imperfections such as handling marks, straightening
marks, tight mandrel, die or roll marks and scale pattern are not to be considered as damaging defects
provided that they do not reduce the wall thickness below the specified tolerance. Surface features
that result in the detachment of metallic flakes from the wall thickness during subsequent bending /
forming shall be considered surface defects.
g)
All tubes are to be cleaned to remove all contamination and moisture. After cleaning, the tube ends
are to be suitably sealed to prevent ingress of moisture and contamination during transport and
storage.
h)
Unless otherwise stated in the contract documents, all tubes are to be supplied in straight random
lengths of not more than 6.0 metres. 90% or more of tubes in each batch are to have a minimum
length of 3.5 metres. The remainder may be supplied in shorter lengths down to a minimum of 2
metres.
13
Test Methods and Examination Requirements
8.1
Selection of Originating Standards
a)
Tubes supplied to this Defence Standard shall be defined by material and dimensions in accordance
with an internationally recognised Originating Standard (as defined in clause 5.2d).
b)
Examples for 70/30 copper-nickel tubing:

1)
Originating Standard: BS EN 12449, Material: CuNi30Mn1Fe / CW345H, Condition R370, OD:

20mm, Wall thickness: 3.5mm.
2)
Originating Standard: Annex C of this Defence Standard, Class 2, OD: 20mm, Wall thickness:
3.5mm.
c)
The design decisions and assumptions, as outlined in clause 5.1, used to select a given tube size and
material from a chosen Originating Standard shall be formally recorded.
8.2
Destructive Tests
Tubes shall be tested and accepted according to the requirements of the chosen Originating Standard.
These requirements must address the issues detailed below, as applicable.
8.2.1
Sampling
Samples need to be taken from material representative of the supplied product, both in terms of
compositional origin and of the processing history to the final product form. When large amounts of tubing
are supplied from different production batches, samples may be required from each batch to ensure
uniformity of properties. Sampling from each production batch / cast is required for First Level components.
8.2.2
Chemical Analysis
Required to confirm compliance of the supplied material with the Originating Standard. Deviations in this
composition may affect tube performance in ways not otherwise detected by other acceptance testing.
Chemical analysis per batch / cast is required for all First Level components.
8.2.3
Tensile Tests
Required to confirm that the mechanical properties of the supplied tubes meet the design assumptions used
to select the tube dimensions. Deviations in mechanical properties may indicate that the wider tube
performance will not be as assumed in the original design decision. Tensile testing per batch is required for
all First Level components.
8.2.4
Hardness Tests
Required to ensure that tube surface mechanical properties do not deviate significantly from tensile test
results obtained from full wall thickness sample. Excessive hardness, especially in surfaces, can make
tubes more difficult to install / assemble and prevent effective use of mechanical couplings which use
metallic teeth or edges to engage the tube surface. If hardness values are specified in the Originating
Standard, First Level components require the hardness testing of each batch.
8.2.5
Re-tests
The repeat testing of a batch of tubes which initially fail to meet the specified performance levels must be
limited to a reasonable level to ensure that any passing test result is truly representative of the tube
performance.
14

8.3
Non-destructive Tests
The following non-destructive testing shall be required for all tubing meeting the requirements of this
Defence Standard. These tests and examinations ensure that manufactured tubes meet the high integrity
and safety requirements of applications in HM Submarines and Surface Ships not in Class.
8.3.1
Visual Examination
The surface of each tube is to be inspected, including internal surfaces where visible from the tube ends.
Magnification optics (up to x 5) may be used if required.
8.3.2
a)
8.3.3
a)
Dimensional Inspection
Each tube is to be checked for dimensional accuracy as follows:

1)
The outside diameter of each tube is to be measured in two directions at 90 in the same plane,
at positions approximately 75 mm from both ends of the tube.
2)
The wall thickness is to be measured at two positions 180 apart at one end of each tube,
unless otherwise specified in Annexes B to E.
Leak Tightness Tests
Each tube shall be tested for defects by one of the following methods at the option of the supplier,
unless otherwise stated in the order:
1)
Eddy current test.
2)
Hydrostatic test.
3)
Pneumatic test (heat exchanger tubes only).
8.3.3.1 Eddy Current Test
The test is to be carried out in accordance with the procedure described in clause A.3.1
8.3.3.2 Hydrostatic Test
a)
Non-heat exchanger tubes are to be hydrostatically tested at room temperature at a test pressure as
defined below, or at 69 bar, whichever is lower:
Test pressure P (bar) = 20
ST
D
Where:
D is the specified outside diameter of the tube (mm).
T is the specified wall thickness of the tube (mm).
S is the stress (MPa) - corresponding to 70% of the specified minimum yield strength or
proof strength for the tube material concerned at room temperature.
b)
The test pressure is to be maintained for at least 30 seconds. During the test the tube is to be
inspected along its entire length.
15

8.3.3.3 Pneumatic Test (Heat Exchanger Tubes only)
Each heat exchanger tube is to be subjected to a pneumatic test. The test pressure is to be 4 bar. The test
duration is to be at least 30 seconds.
8.3.4
a)
Pressure Proof Test
Each general purpose tube (not heat exchanger tube) shall be pressure proof tested to indicate
suitability for the operating pressures to be employed. The test pressure is to be:
1)
times the system Design Pressure if this is less than or equal to 70 bar, or
2)
1.5 times the system Design Pressure if greater than 70 bar.
b)
The test pressure is to be maintained for at least 30 seconds. During the test the tube is to be
inspected along its entire length.
c)
Where the leak tightness tests (clause 8.3.3) selected is a hydrostatic test (clause 8.3.3.2) requiring a
test pressure greater than the system-based proof test pressure defined in clause 8.3.4a), a
successful hydrostatic test shall be considered to also meet the requirements of this pressure proof
test.
8.3.5
Magnetic Permeability
This is only to be measured when stipulated in the contract documents, using the stipulated method.
8.3.6
Ultrasonic Tests
After acceptance of the leak tightness and pressure tests, each tube for First Level applications is to be
subjected to an ultrasonic test. Ultrasonic testing of Non-First Level tubes shall also be carried out if
stipulated by the contract documents. The test is to be carried out in accordance with the procedure
described in clause A.3.2.
Acceptance Standards
Tubes shall be accepted in accordance to their Originating Standard (as defined in 5.2d) and 8.1) and with
the following requirements, where additional:
9.1
9.1.1
Destructive Tests
Chemical Analysis
The analysis of each cast and batch of tubes is to conform to the chemical composition in the material
standard specified under clause 8.1. Only the result of the tube analysis is to appear on the quality
assurance documentation.
9.1.2
Mechanical Properties Tests
The mechanical properties established from the tensile tests under clause 8.2.3 are to conform to the
material standard specified under clause 8.1.
9.1.3
Hardness Test
The hardness value is to conform to material standard specified under clause 8.1, as applicable.
16

9.2
9.2.1
Visual Examination
a)
The external and internal surfaces of each tube is to be clean, smooth, bright and free from visible
defects, contamination and moisture. Dressed areas are to be faired smoothly into the surrounding
material, in compliance with clause 7f) and the relevant minimum tolerance on tube dimensions.
b)
All tube ends are to be clean cut and square with the axis and are to be free from burrs.
c)
All tubes are to be free from local bends or kinks.
9.2.2
Dimensional Checks
Tubes shall comply with the dimensions specified by the standard selected under clause 5.2d). Deviations
from circularity (such as ovality and off-centre bore) shall be acceptable if such tubes comply with the
required wall thickness and outside diameter values at all points of their circumference.
9.2.3
Leak Tightness Tests
9.2.3.1 Eddy Current Test
No tube is to cause a signal which is equal to or greater than that caused by the standard reference specified
in clause A.3.1. Tubes giving rise to signals in excess of the agreed calibration level are to be rejected
without the need to record the location, extent and signal amplitude.
9.2.3.2 Hydrostatic Test
Each general purpose tube is to withstand the test pressure without leaking, bulging or revealing any other
defect.
9.2.3.3 Pneumatic Test (Heat Exchanger Tubes only)
Each condenser and heat exchanger tube is to show no evidence of leakage.

9.2.4
Pressure Proof Test
Each general purpose tube is to withstand the test pressure without leaking, bulging or revealing any other
defect.
9.2.5
Magnetic Permeability
The magnetic permeability is to conform to the requirements of the contract.

9.2.6
Ultrasonic Tests
No tube is to cause a signal which is equal to or greater than that caused by the standard reference specified
in clause A.3.2. Tubes giving rise to signals in excess of the agreed calibration level are to be rejected
without the need to record the location, extent and signal amplitude.
9.3
Rejection
Tubes failing to meet any of the requirements of clauses 9.1 and 9.2 are to be rejected.
17

9.4
Summary of Tube Procurement Process
A schematic of the tube selection and procurement process is shown in Figure 2.
Identify tube system

requirements (including
pipe diameter)
NO
Replacing
existing tubes
on like-for-like
basis?
YES
Select Def Stan 02-878

Annex equivalent to
superseded Def Stan or
NES of original tubes
Select tube material for

strength, corrosion, cost
and other properties
(Clause 5.1c))
Select appropriate tube

dimensions from those
listed in Annex
Select Originating
Standard (Clause 8.1),
either commercial or
Def Stan 02-878 Annex
Test tubes for

compliance with Annex
requirements
Calculate minimum wall

thickness based on
Design Pressure and
minimum strength of
specified material
(Clause 5.6)
Add any
bending/corrosion
allowances to minimum
wall thickness
Record design process

decisions and
assumptions for future
reference
Select next available

tube size greater than
calculated wall
thickness requirement
Test tubes for

compliance with
Test tubes for

compliance with NonDestructive tests
detailed in Clauses
8.3 and 9.2
Accept tubes for use

and prepare QA records
Figure 2 Schematic Flowchart for Tube Procurement Process
18
10
Quality Assurance Documentation
10.1 General
a)
Unless otherwise specified in the order or contract, each consignment of tubes is to be accompanied
by quality assurance documentation giving the actual results of the compositional, tensile and
hardness tests required by clauses 8.2.2, 8.2.3 and 8.2.4, and other information and results required
by the Originating Standard.
b)
The quality assurance documentation which accompanies First Level Quality Assured tubes is to
satisfy all the requirements of SSP 25.
c)
The documentation is to include a certificate of conformity.
d)
Documentation is to be forwarded to the consignee in a separate enclosure.
10.2 Certificate of Conformity

a)
Each certificate is to include a statement that the material complies with all the requirements of this
Defence Standard, supported by the signature of an authorized inspector.
b)
Each certificate is to carry a reference number or sufficient other information to positively relate the
certificate with the relevant tubing.
10.3 Records
Records sufficient to prove adequate quality control, full material traceability and the relevant results of
analyses and tests are to be retained by the contractor for at least 5 years after delivery. After the 5 year
period destruction of the records shall be as defined in the contract.
11
Identification
a)
Each box of tubes prepared for delivery is to be indelibly marked with the following (in the stated
order):
1)
The manufacturers name or identification mark.
2)
The Originating Standard, with Annexes of the Defence Standard marked e.g. ABCD- Def Stan
02-878-Annex Y as appropriate.
3)
Description i.e. Size (outside diameter and wall thickness) and maximum Proof Test Pressure
(as per clause 8.3.7). The Class of tubes ordered to Annexes C to E of this standard shall also
be included.
4)
NATO Stock Number (if applicable).
5)
Contract Number.
6)
Quantity.
7)
A reference number or sufficient other information to positively relate the tubing to the relevant
certificate of conformity.
19

b)
Unless otherwise stated in the order or contract, each tube is to be identified with the information
specified in clause 11a) 2), 3) and 7) by the contractor by printing directly onto the outside surface of
the tube using an ink which will not have a deleterious effect on the material. The markings are to be
not less than 5 mm high and are to be repeated along the entire length of the tube. The maximum
distance between markings is not to exceed 300 mm.
c)
Metal stamping or vibro-etching shall not be used for identification marking, unless otherwise specified
by the contract.
20
Annex A
Test Methods Specific to this Defence Standard
A.1 Scope
This Annex details the specific test requirements of tubes procured under this Defence Standard, in addition
to those test methods used by the Originating Standard.
A.2 Flattening and Bend Tests for Copper Alloys

A.2.1
Flattening Test
a)
This test applies to tubes not exceeding 108 mm outside diameter. The test pieces shall be annealed
before flattening unless the tubes are supplied in the annealed condition.
b)
The test pieces shall be flattened down until the interior surface meets as shown below:
c)
The test piece shall show no visible evidence of cracks or flaws.
A.2.2
Double Bend Test
a)
This test applies to round tubes of over 108 mm outside diameter. The test pieces shall be annealed
before flattening unless the tubes are supplied in the annealed condition.
b)
A test piece 50 mm wide shall be cut longitudinally from the tube. The longer edges shall be carefully
rounded and smoothed longitudinally so that a cross section has approximately semicircular ends.
The test piece shall be flattened and shall have its ends bent through 180 in opposite directions and
doubled up close as shown.
c)
The test piece shall show no visible evidence of cracks or flaws.
A.3 Non-destructive Test Procedures

A.3.1
Eddy Current Test
A.3.1.1
a)
Method of Test
All inspections are to be carried out in accordance with Def Stan 02-729 Part 3.
21

b)
The method of test is to be chosen to ensure complete inspection of the whole of the tube wall as
supplied. If the ends of tubes cannot be satisfactorily inspected, the un-inspected areas may be cutoff.
A.3.1.2
Calibration
a)
The sensitivity of the equipment is to be set using a calibration standard.
b)
In each case the calibration standard is to consist of 3 holes of not more than 0.80mm diameter drilled
completely through the tube wall. The holes are to be displaced circumferentially at 120 from one
another and sufficiently far apart axially to ensure that signals from each one can be easily resolved
and are not influenced by signals from either of the other two holes or by end effects.
c)
The holes are to be drilled cleanly and the diameter is not to be enlarged in any way e.g. by deburring
operations on the external or internal surfaces.
A.3.1.3
Checking of Equipment
a)
The control equipment is to be set so that it is triggered by the signal from each hole every time the
calibration standard is put through.
b)
The speed at which the calibration standard passes the test coil is to be the same as will apply to
production testing.
c)
Calibration checks are to be carried out at intervals not exceeding one hour and at the beginning of
each shift.
d)
If on checking, any of the standard holes are not detected, all tubes tested since the last calibration
check are to be re-tested after normal operation has been re-established.
e)
All equipment, techniques and procedures for the inspection of tubes to this Standard are to be
approved by the acceptance authority.
A.3.2
Ultrasonic Test Method
a)
Testing shall be conducted on each tube, after leak tightness tests, pressure testing and magnetic
permeability (if required) tests have been completed.
b)
A.3.2.1
Method of Test
a)
During testing, the tubes or search units are to be moved so that the probes traverse the tube surface
in a helix. The pitch of the helix is to be related to the effective beam width and the minimum flaw to
be positively located such that the whole of the tube wall is effectively scanned. The frequency and
transducer size used is to be compatible with the material and the thickness of the tube being
inspected.
b)
The speed of movement of the probe relative to the tube surface is to be limited to give optimum
inspection conditions.
c)
The probe assembly is to be so arranged that 100% of the internal and external surfaces of the tube is
scanned for both circumferential and longitudinal defects.
d)
The standard immersion technique of using a compression wave probe operated to achieve shear
wave examination is permitted.
22

A.3.2.2
Equipment
Probes up to a maximum dimension of 25 mm diameter are permitted for use. All equipment, techniques
and procedures for the inspection of tubes to this Standard are to be approved by the Acceptance Authority.
A.3.2.3
Calibration Standards
a)
The ultrasonic equipment is to be calibrated using a longitudinal and transverse standard notch on the
outside and inside surfaces of a tubular test piece of the same specification as the tubes for
inspection, in the as supplied condition.
b)
External and internal standard notches are to be sufficiently separated axially as to be completely
distinguishable.
c)
For tubes 12 mm bore and below, the internal notch may be omitted. In the absence of an internal
notch, bore defects will be identified by reference to the depth range of position of the cathode ray
tube display. The alarm monitor is to be positioned to include the depth range at which bore defects
will be indicated, i.e. at the midway position between the first and second outside surface defect
positions. The alarm monitor sensitivity is to be set to the level defined by the outside surface notch.
d)
The standard notch is to comply with the following:

1)
Manufacture - the notch is to be formed either by machining or spark erosion.
2)
Shape - the cross section of the notch is to be nominally of rectangular section; other sections
are to be adopted only by agreement with the Acceptance Authority.
3)
Length - standard longitudinal notch 25 mm maximum. Standard transverse notch may extend
fully round the circumference.
4)
Width - standard notch width - 1mm maximum.
5)
Depth - the standard notch depth is to be 3% of the specified wall thickness or 0.1 mm,
whichever is greater, unless otherwise agreed between the acceptance authority and the
Contractor. There is to be no positive tolerance on the depth of notch. The internal notch is not
to be used when the outside diameter to thickness ratio is less than 4. For outside diameter to
thickness ratios between 5 and 4, the internal standard notch depth is to be in accordance with
Table A.1.
Table A.1 Ultrasonic Calibration Notch Depths
Ratio of Outside Diameter to
Thickness
Ratio of Internal Notch Depth to

External Notch Depth
4.75 to 4.99
1.6
4.50 to 4.74
1.9
4.25 to 4.49
2.2
4.00 to 4.24
2.5
23

A.3.2.4
Calibration and Checking of Equipment
a)
The ultrasonic equipment is to be set so that it is triggered by the signals from both the internal and
external standard notches every time the calibration standard notch is used. The relative rotational
speed between the tube containing the standard notch and the search unit during calibration is to be
the same as will apply during testing.
b)
each shift.
c)
If on checking during production testing either or both standard notches are not detected, then all
tubes tested since the previous check are to be re-tested after the instrument has been recalibrated.
A.3.3
Ultrasonic Thickness Gauging
A.3.3.1
Method of Test
a)
During testing the tubes or search units are to be moved so that the probes traverse the tube surface
in a helix. The pitch of the helix is to be determined by the application of clause A.3.2.1a).
b)
The speed of movement of the probe relative to the tube surface must be limited to give optimum
inspection conditions.
c)
Variations in tube wall thickness are to be inspected by a longitudinal wave technique.
d)
The frequency and transducer size used is to be compatible with the material and the thickness of the
tube being inspected.
A.3.3.2
Calibration Standards
The ultrasonic equipment is to be calibrated using a tube of known thickness with areas of minimum and
maximum wall thickness.
A.3.3.3
Calibration and Checking of Equipment
a)
The ultrasonic equipment is to be set so that it is triggered by the signals from the minimum and
maximum wall thickness every time the calibration standard is used. The relative rotational speed
between the calibration standard tube and the search unit during calibration is to be the same as will
apply during testing.
b)
each shift.
c)
If on checking during production testing, the minimum or maximum wall thicknesses are not detected,
then all tubes tested since the previous check are to be retested after the instrument has been
recalibrated.
d)
All equipment, techniques and procedures for the inspection of tubes to this Standard are to be
approved by the acceptance authority.
24
Annex B
Specific Requirements for Copper Tubes
(previously covered by Def Stan 02-837)
B.1 Scope
This Annex specifies the specific requirements for the manufacture, inspection, testing and supply of copper
tubes formally covered by Def Stan 02-837. The copper tubes meet the requirements for phosphorus
deoxidised non-arsenical copper conforming to the chemical composition of BS EN 12449, Material Symbol
Cu-DHP, Material Number CW024A (referred to as BS EN 12449 CW024A throughout this standard) and
does not cover any other Material Symbol or Material Number listed in BS EN 12449.
B.2 Manufacture
B.2.1
Tube production
Unless otherwise stated in the contract documents, all tubes are to be made to the dimensions detailed in
Tables B.1 to B.6.
B.2.2
Condition of Tubing
a)
Straight tube may be supplied in the R200, R250, R290 or R360 condition and Coiled tube shall be
supplied in the R200 (Annealed) condition in accordance with the requirements of BS EN 12449
CW024A.
b)
If required by operational conditions, Bright Annealing (R200) may be specified on the order.
c)
To satisfy hydrostatic pressure test requirements, materials of a higher tensile strength (R250, R290 or
R360) may be specified. Improved material properties may be achieved by cold drawing post the
annealing process. This condition has previously been referred to as the Half-hard condition.
B.2.3
Supply Requirements
a)
The order or contract shall state the form of tubing that shall be supplied if different from the normal
forms of supply detailed below.
b)
Tubes up to and including 10 mm Outside Diameter (OD) shall be supplied in coils. Coiled tube shall
be supplied in bunched coils in accordance with the requirements of BS EN 12449.
c)
Tubes larger than 10 mm shall be supplied in straight lengths in accordance with the requirements of
BS EN 12449.
d)
Unless otherwise specified in the order or contract or agreed between purchaser and supplier, straight
tube shall be supplied in random lengths of not less than 3.5 metres and not more than 6.0 metres.
e)
Unless otherwise specified in the order or contract or agreed between purchaser and supplier, coils
shall be approximately 750 mm outside diameter.
f)
Tubes supplied for refrigeration systems must be supplied dehydrated and with sealed ends.
25
B.3 Specific Tests

Tests shall be in accordance with clause 8, with the following additional specific requirements.
B.3.1
Destructive Tests
B.3.1.1
Mechanical Test Sampling
a)
Straight Tube - Mechanical test samples shall be selected at the minimum rate of one tube in every
1300 kg of tubing or a minimum of one tube in every 300 tubes of the same size, whichever gives the
larger number of samples.
b)
Coiled Tube - Mechanical test samples shall be taken from coils selected at the minimum rate of one
coil in every 1300 kg of tubing of the same size.
c)
All Tube - Where a production run contains less than 1300 kg of tubing or less than 300 straight tubes
of the same size, one straight tube or part of one coil shall be selected as a test sample for each size
of tubing.
B.3.1.2
Chemical Analysis
a)
A full chemical analysis shall be made from a sample taken from each cast and from each material
taken from each tube or coil selected for mechanical tests.
b)
If no material is available from the tube or coil used for mechanical tests, one further sample tube or
coil shall be similarly selected and used for analysis.
B.3.1.3
Mechanical Tests
a)
Tensile properties are to be determined in accordance with BS EN ISO 6892-1.
b)
Hardness properties are to be determined in accordance with BS EN ISO 6507-1.
c)
Retests shall be conducted as described in BS EN 12449.
B.3.2
These shall be performed as specified in clause 8.3.
B.3.2.1
Samples for Dimensional Checks
a)
For tubing up to and including 75 mm OD, sample tubes shall be selected for dimensional
examination. Sampling shall be carried out at the minimum rate of one in every 300 tubes or a
minimum of one tube in every production run of less than 300 tubes.
b)
For tubing over 75 mm OD every tube shall be examined.
26
B.4 Acceptance Criteria

B.4.1
Chemical Analysis
As specified in BS EN 12449 CW024A.
B.4.2
Mechanical Tests
a)
Tensile properties are to comply with stated material grade in BS EN 12449 CW024A.
b)
Hardness properties are to comply with stated grade in BS EN 12449 CW024A.
B.4.3
a)
Visual examination of the tube surfaces shall meet the requirements of clause 9.2.1. All tubes shall be
free from local bends and kinks.
b)
Dimensions shall meet the tolerances of BS EN 12449 and Tables B.1 to B.6.
c)
Leak tightness and pressure tests shall meet the requirements of clause 9.2.3.
B.4.4
Rejection
Tubes failing to meet the requirements of clause B.4 shall be rejected.
B.5 Identification
Material description in addition to requirements of clause 11 shall be BS EN 12449-CW024A Def Stan 02878 Annex B.
27

Table B.1 Metric Tube for Fresh Water, Oil and LP Air Systems for use at
Working Pressures up to 6 bar and Temperatures up to 75C
Tube Dimensions based on BS EN 12449 (mm)
Nominal size
(mm)
Outside Diameter
Wall Thickness
Max
Min
Nom
Max
Min
6.06
5.94
0.8
0.92
0.68
8.06
7.94
0.8
0.92
0.68
12
12.08
11.92
0.8
0.92
0.68
15
15.08
14.92
1.0
1.15
0.85
22
22.12
21.88
1.2
1.356
1.044
28
28.12
27.88
1.2
1.356
1.044
35
35.15
34.85
1.5
1.695
1.305
42
42.15
41.85
1.5
1.695
1.305
54
54.20
53.80
2.0
2.26
1.74
76.1
76.30
75.90
2.0
2.26
1.74
Table B.2 Imperial Tube for: (a) Steam Systems at Working Pressures up to 10.5 bar and
Temperatures up to 187C and (b) General use up to 12 bar and Temperatures up to 175C
Tube Dimensions based on BR 3013 (1),
Parts 1 and 2 (inches)
Nominal Size
Bore (inches)
Outside Diameter
Max
28
Min
Wall Thickness
Nom SWG
0.125
See Table B.3
0.25
See Table B.4
0.375
See Table B.3
Max
Min
0.5
0.596
0.593
16
0.070
0.058
0.75
0.846
0.843
16
0.070
0.058
1.0
1.112
1.109
15
0.078
0.066
1.25
1.362
1.359
15
0.078
0.066
1.50
1.612
1.609
14
0.090
0.070
2.0
2.128
2.125
13
0.102
0.082
2.5
2.628
2.622
12
0.114
0.094
3.0
3.144
3.138
11
0.126
0.106
4.0
4.184
4.178
0.157
0.131
5.0
5.455
5.445
0.189
0.163

Table B.3 Imperial Tube for: (a) Steam Systems at Working Pressures up to
17 bar and Temperatures up to 208C and (b) General use at Working
Pressures up to 25 bar and Temperatures up to 190C
Nominal Size
Bore (inches)
Outside Diameter
0.125
Wall Thickness
Max
Min
Nom
SWG
Max
Min
0.205
0.202
18
0.054
0.042
0.25
See Table B.4
0.375
0.471
0.468
16
0.070
0.058
0.5
0.596
0.593
15
0.078
0.066
0.75
0.847
0.843
13
0.102
0.082
1.0
1.112
1.109
12
0.114
0.094
1.25
1.362
1.359
11
0.126
0.106
Table B.4 Imperial Tube for: (a) Pressure Gauge Piping for use at Working Pressures
up to 83 bar and Temperatures up to 75C and (b) Steam Systems at Working
Nominal Size
Bore
Outside Diameter
(inches)
0.25
Wall Thickness
Max
Min
Nom
SWG
Max
Min
0.346
0.343
16
0.070
0.058
Table B.5 Metric Tube for Refrigeration Systems at Working

Pressures up to 11 bar and Temperatures to 75C
Tube Dimensions based on BS EN 12449 (mm)
Nominal Size
(mm)
Outside Diameter
Wall Thickness
Max
Min
Nom
Max
Min
6.06
5.94
1.0
1.15
0.85
12
12.08
11.92
1.0
1.15
0.85
15
15.08
14.92
1.0
1.15
0.85
28
28.12
27.88
1.0
1.15
0.85
29

Table B.6 Imperial Tube for Refrigeration Systems at Working
Tube Dimensions (inches)
Nominal Size
(inches)
30
Outside Diameter
Wall Thickness
Max
Min
Nom
SWG
Max
Min
0.188
0.190
0.186
20
0.040
0.032
0.250
0.252
0.248
20
0.040
0.032
0.375
0.377
0.373
20
0.040
0.032
0.5
0.502
0.498
20
0.040
0.032
0.625
0.627
0.623
20
0.040
0.032
0.750
0.752
0.749
19
0.044
0.036
0.875
0.877
0.874
18
0.053
0.043
1.125
1.127
1.124
16
0.070
0.058
Annex C
Specific Requirements for 70/30 Copper-nickel Alloy Tubes
(previously detailed in Def Stan 02-780 Part 3)
C.1 Scope
a)
This Annex specifies the requirements for the manufacture, inspection, testing and supply of 70/30
copper nickel alloy tubes previously covered by Def Stan 02-780 Part 3.
b)
The tubes supplied against this Annex are for general purpose and heat exchanger / condenser use
only. Where tubes are required for a special purpose, e.g. an oxygen clean system, this should be
specified in the contract documents together with any special cleaning requirements and the required
acceptance standards.
c)
70/30 copper-nickel alloy tubes are placed in eight classifications (Classes 2-9 inclusive) dependent
upon material condition, usage, and wall thickness. The classification does not denote the level of
quality assurance.
C.2 Tube Classification

a)
The classification of tubes is according to usage, dimensional units and material condition and is
defined in Table C.1. Any subsequent stroke number denotes maximum working pressure in either
psi for imperial tubes or bar for metric tubes.
b)
All tubes are to be designated by class, outside diameter, wall thickness and length.
C.3 Manufacture
C.3.1
Tube Production
Tables C.2 and C.3. For condenser and heat exchanger tubes the requirements of Def Stan 02-329 must
also be met.
C.3.2
Condition of Tubing
a)
General purpose tubes are to be supplied in the fully annealed condition.
b)
Condenser and heat exchanger tubes are to be supplied in either the hard or the annealed condition,
dependent upon the requirements of the contract documents. When the hard condition is specified,
i.e. Class 5 and 8, the tubes are to be given a low temperature stress relieving treatment.
c)
All tubes are to be cleaned to remove all contamination and moisture. After cleaning, the tube ends
are to be suitably sealed to prevent ingress of moisture and contamination during transport and
storage.
C.3.3
Supply Requirements
Unless otherwise stated in the contract documents, all tubes are to be supplied in straight random lengths of
not more than 6.0 metres. 90% or more of tubes in each batch are to have a minimum length of 3.5 metres.
The remainder may be supplied in shorter lengths down to a minimum of 2 metres.
31
C.4 Specific Tests

C.4.1
Destructive Tests
C.4.1.1
Sampling for Destructive Tests
Tests shall be made on a test sample taken from each batch of tubes in the as supplied condition.
C.4.1.2
Chemical Analysis
A full chemical analysis shall be made from a sample taken from each cast and from batch of tubes in the as
supplied condition.
C.4.1.3
Mechanical Tests
a)
b)
c)
A flattening or double bend test shall be carried out as detailed in clause A.2.
d)
C.4.2
These shall be performed as specified in clause 8.3, in addition to:

C.4.2.1
The wall thickness at both ends of each tube is to be measured at four positions 90 apart.
C.4.2.2
Ultrasonic Wall Thickness Checks
Additional ultrasonic thickness testing to clause A.3.3 may be optionally required and stated in the contract
documents.
C.5 Acceptance Criteria

C.5.1
Destructive Tests
C.5.1.1
Chemical Analysis
Chemical analysis of each cast and each batch of tubes shall conform to Table C.4.
C.5.1.2
Mechanical Tests
a)
The specified tensile tests shall conform to the values in Table C.5.
b)
The specified hardness test shall conform to the values in Table C.5.
c)
In the flattening or bending test the tubing is to show no visible evidence of cracks or flaws.
32

C.5.2
a)
b)
Dimensions shall meet the requirements of Tables C.2 to C.3 and the tolerances of Tables C.6 to C.7.
All condenser and heat exchanger tubes are to have ends cut clean and square to within 1mm.
c)
d)
Ultrasonic testing is to comply with the requirements of clause 9.2.6.
e)
If ultrasonic wall thickness gauging is required, tube is to be rejected where the wall thickness is
outside the thickness tolerance (Tables C.6 to C.7), without the need to record where the thickness
approaches the minimum tolerance on good or rejected tubes.
C.5.3
Rejection
Tubes failing to meet the requirements of clause C.5 shall be rejected.
C.6 Identification
Material description in addition to requirements of clause 11 shall be 70/30 CuNi Def Stan 02-878
Annex C and shall also detail the Class and Test Pressure.
Table C.1 Classification of Tubes
Dimensions
Class
Material
Usage
Condition
Metric
See Annex D: Requirements for 90/10 copper-nickel alloy tubes
70/30CuNi
General Purpose (Sea

Water Systems)
70/30CuNi
Imperial
ANNEALED
General Purpose (High

Pressure > 1000psi)
ANNEALED
70/30CuNi
Condenser & Heat

Exchanger
ANNEALED
70/30CuNi
Condenser & Heat

Exchanger
HARD
70/30CuNi
General Purpose (High

Pressure > 70 Bar)
ANNEALED
70/30CuNi
Condenser & Heat

Exchanger
ANNEALED
70/30CuNi
Condenser & Heat

Exchanger
HARD
70/30CuNi
General Purpose (Thin

Wall For MCMVs)
ANNEALED
33

Table C.2 70/30 Copper-nickel Alloy Tubes - General Purpose (metric)
Nominal
External
Diameter
(mm)
34
Tube Classification
(Class-Working pressure in bar)
2-28
2-69
6-207
6-280
9-10
9-16
Wall Thickness (mm)
1.0
1.0
0.8
1.0
1.5
1.5
1.5
1.5
0.8
1.0
10
2.0
12
12 (butt welded
applications)
16
2.5
2.5
2.5
2.5
0.8
1.0
3.0
3.0
3.0
3.0
3.0
3.0
3.0
1.0
1.5
20
3.5
3.5
3.5
3.5
1.0
2.0
25
1.5
2.0
30
2.5
4.0
4.0
5.0
1.5
2.0
38
2.5
4.0
5.0
6.5
1.5
2.0
44.5
3.0
4.0
8.0
1.5
2.0
50
3.0
6.5
8.5
57
3.0
5.0
7.5
9.5
1.5
2.0
76.1
3.5
6.0
10.5
13.0
2.0
2.5
88.9
4.0
2.5
3.0
100
2.5
3.0
108
4.0
7.5
2.5
3.0
133
4.5
9.0
2.5
3.0
162
11.0

Table C.3 70/30 Copper-nickel Alloy Tubes. General Purpose (imperial):
Dimensions, classification and working pressures
Outside
Diameter
(inches)
Nominal
Bore
(inches)
Actual
Bore
(inches)
Tube Classification
(Class-Working Pressure in psi)
2-200
2-350
2-700
3-3000
3-4000
3-4500
Wall Thickness (inches)

0.250
0.346
0.405
/8
0.471
/8
0.035
0.049
0.058
0.064
0.062
0.065
0.064
0.500
0.035
0.072
0.109
0.134
0.540
0.065
0.072
0.109
0.134
0.548
0.596
0.675
0.078
0.064
/8
0.721
0.840
0.846
0.900
1.050
1.112
1.112
1.315
1.362
1.362
0.065
0.072
0.086
0.083
0.120
0.165
0.083
0.148
0.180
0.165
0.220
0.064
0.065
0.072
0.064
0.072
0.065
0.095
0.172
0.080
0.065
0.095
0.109
0.203
0.259
0.210
0.092
1.612
1.660
0.072
0.095
0.092
0.120
0.238
0.340
1.900
0.072
0.109
0.134
0.259
0.340
2.128
0.080
0.116
0.144
0.080
0.116
2.375
2.628
0.120
2.875
3.144
0.092
0.128
0.176
3.660
0.092
0.144
0.192
4.000
4.184
0.104
0.160
0.212
4.955
0.116
0.176
0.252
5.384
0.116
0.192
0.252
5.563
6.424
7.464
0.318
0.300
0.425
0.160
0.134
0.380
0.165
0.203
0.128
0.212
0.300
0.348
0.144
0.232
0.144
0.252
0.160
0.276
10
0.300
11
0.375
35

Table C.4 Chemical Composition
Per Cent by Weight
Element
Not Less Than
Not More Than
Nickel
30.0
32.0
Manganese
0.5
1.5
Iron
0.6
1.0
Copper
Remainder
Impurities
Aluminium
0.03
Bismuth
0.002
Boron
0.02
Carbon
0.06
Lead
0.01
Phosphorus
0.01
Silicon
0.05
Sulphur
0.02
Total Impurities
0.30
Table C.5 Room Temperature Mechanical Properties

Minimum
0.2%
Proof Stress
(MPa)
Minimum
Elongation on
5.65 So Gauge
length (%)
Minimum
Maximum
2, 3, 4, 6, 7 and 9
400
140
35
110
5 and 8
480
400
16
150
Class
36
Hardness
(HV)
Minimum
Tensile
Strength
(MPa)

Table C.6 Tolerances for General Purpose Tubes
Classes 2&6 (Metric)
Nominal Tube
Size (mm)
Up to but
From
not
including
Tolerance On
Outside Diameter (mm)
* Specified Thickness
Plus
Minus
Plus
Minus
20
0.05
0.04
15%
0%
20
35
0.06
0.03
15%
0%
35
55
0.07
0.01
15%
0%
Class 9 (Metric)
All dimensions
All sizes
To be in accordance with requirements of BS EN 12449
Classes 2&3 (Imperial)

Nominal Tube
Size (inches)
Up to but
From
not
including
Tolerance On
Outside Diameter (inches)
* Specified Thickness
Plus
Minus
Plus
Minus
0.250
1.660
0.000
0.003
15%
0%
1.660
5.384
0.000
0.006
15%
0%
5.384
7.500
0.010
0.000
15%
0%
* Maximum deviation at any point. The eccentricity of the bore relative to the outside diameter is not to
be greater than the thickness tolerance will permit.
37

Table C.7 Tolerances for Condenser and Heat Exchanger Tubes
Classes 7&8 (Metric)
Dimension
Range
Up to and including
Outside
Diameter
50mm
Thickness*
All Sizes
Length**
30m
Tolerance
To be in accordance with requirements of

BS EN 12451
Classes 4&5 (Imperial)
Dimension
Range
Up to and including
Tolerance (inches)
Plus
Minus
Outside
Diameter
1 inches
0.000
0.006
Thickness*
17 SWG
0.004
0.004
Length**
All Sizes
0.031
0.000
*
The eccentricity of the bore relative to the outside diameter is not to be greater than the thickness
tolerance will permit, which is to be the maximum deviation at any point.
**
The tolerance on straightness is to be 6mm total envelope in any 3m for metric tubes and 0.250
inches total envelope in any 10 feet for Imperial tubes.
38
Annex D
Specific Requirements for 90/10 Copper-nickel Alloy Tubes
(previously covered by Def Stan 02-779 Part 3)
D.1 Scope
a)
This Annex specifies the requirements for the manufacture, inspection, testing and supply of 90/10
copper-nickel alloy tubes previously covered by Defence Standard 02-779 Part 3.
b)
The tubes supplied against this Annex are for general purpose use only. Where tubes are required for
a special purpose, e.g. an oxygen clean system, this should be specified in the contract documents
together with any special cleaning requirements and the required acceptance standards.
D.2 Tube Classification

The tubes are Class 1 (see Table D.1). The class number denotes the usage and wall thickness. The
classification does not denote the level of quality assurance.
D.3 Manufacture
D.3.1
Tube production
Tables D.1 to D.3. For condenser and heat exchanger tubes the requirements of Def Stan 02-329 must also
be met.
D.3.2
Condition of Tubing
All tubes are to be supplied in the fully annealed condition.
D.3.3
Supply Requirements
D.4 Specific Test Methods

D.4.1
D.4.1.1
Destructive Tests
Tests shall be made on a test sample taken from each batch of tubes in the as supplied condition.
D.4.1.2
Chemical Analysis
supplied condition.
39

D.4.1.3
Mechanical Tests
a)
b)
c)
A flattening or double bend test shall be carried out as detailed in clause A.2.
d)
D.4.2

D.4.2.1
D.4.2.2
documents.
D.5 Acceptance Criteria

D.5.1
Destructive Tests
D.5.1.1
Chemical Analysis
Chemical analysis of each cast and each batch of tubes shall conform to BS EN 12449- CW352H, except
that for seawater applications the iron content shall be at least 1.5%. This increased iron content is to
ensure resistance to seawater erosion-corrosion.
D.5.1.2
Mechanical Tests
a)
The specified tensile tests shall conform to the values in Table D.4.
b)
The specified hardness test shall conform to the values in Table D.4.
c)
In the flattening or bending test the tubing is to show no visible evidence of cracks or flaws.
D.5.2
a)
b)
Dimensions shall meet the requirements of Tables D.1 to D.3. All condenser and heat exchanger
tubes are to have ends cut clean and square to within 1mm.
c)
d)
e)
outside the thickness tolerance, without the need to record where the thickness approaches the
minimum tolerance on good or rejected tubes.
40

D.5.3
Rejection
Tubes failing to meet the requirements of clause D.5 shall be rejected.
D.6 Identification
Material description in addition to requirements of clause 11 shall be 90/10 CuNi Def Stan 02-878
Annex D and shall also detail the Class and Test Pressure.
Table D.1 Class 1-175 Imperial Tubes (working pressure 175 psi)
Tube Dimensions (inches)
Nominal
Size
(inches)
Mean Outside
Diameter
Wall Thickness
Maximum
Minimum
Nominal
Maximum
Minimum
0.5
0.596
0.593
0.048
0.053
0.043
0.75
0.846
0.843
0.048
0.053
0.043
1.0
1.112
1.109
0.056
0.062
0.050
1.25
1.362
1.359
0.056
0.062
0.050
1.5
1.612
1.609
0.056
0.062
0.050
2.0
2.128
2.122
0.064
0.070
0.058
2.5
2.628
2.622
0.064
0.070
0.058
3.0
3.144
3.138
0.072
0.079
0.065
3.5
3.660
3.654
0.080
0.088
0.072
4.0
4.184
4.178
0.092
0.102
0.083
6.0
6.208
6.198
0.104
0.117
0091
8.0
8.208
8.198
0.104
0.117
0.091
41

Table D.2 Data for Class 1-10 Metric Tubes (working pressure 10 bar)
Tube Dimensions (mm)
Nominal
Size
(mm)
42
Mean Outside
Diameter
Wall Thickness
Maximum
Minimum
Nominal
Maximum
Minimum
6.045
5.965
0.8
0.88
0.72
8.045
7.965
0.8
0.88
0.72
12
12.045
11.965
0.8
0.88
0.72
16
16.045
15.965
1.0
1.1
0.9
20
20.055
19.975
1.0
1.1
0.9
25
25.055
24.975
1.5
1.65
1.35
30
30.055
29.975
1.5
1.65
1.35
38
38.070
37.990
1.5
1.65
1.35
44.5
44.570
44.490
1.5
1.65
1.35
57
57.200
57.120
1.5
1.65
1.35
76.1
76.300
76.150
2.0
2.2
1.8
88.9
89.150
89.000
2.5
2.75
2.25
108
108.25
108.00
2.5
2.75
2.25
133
133.50
133.25
2.5
2.81
2.19
159
159.50
159.25
2.5
2.81
2.19
193.7
194.50
194.25
3.0
3.38
2.625
219.1
219.90
218.30
3.0
3.38
2.625
267
268.00
266.40
3.0
3.38
2.625

Table D.3 Data for Class 1-16 Metric Tubes (working pressure 16 bar)
Tube Dimensions (mm)
Nominal
Size
(mm)
Mean Outside
Diameter
Wall Thickness
Maximum
Minimum
Nominal
Maximum
Minimum
6.045
5.965
1.0
1.1
0.9
8.045
7.965
1.0
1.1
0.9
12
12.045
11.965
1.0
1.1
0.9
16
16.045
15.965
1.5
1.65
1.35
20
20.055
19.975
2.0
2.2
1.8
25
25.055
24.975
2.0
2.2
1.8
30
30.055
29.975
2.0
2.2
1.8
38
38.070
37.990
2.0
2.2
1.8
44.5
44.570
44.490
2.0
2.2
1.8
57
57.200
57.120
2.0
2.2
1.8
76.1
76.300
76.150
2.5
2.75
2.25
88.9
89.150
89.000
3.0
3.3
2.7
100
100.25
100.00
3.0
3.3
2.7
108
108.25
108.00
3.0
3.3
2.7
133
133.50
133.25
3.0
3.38
2.63
159
159.50
159.25
3.0
3.38
2.63
193.7
194.50
194.25
3.5
3.94
3.06
219.1
219.90
218.30
4.0
4.5
3.5
267
268.00
266.40
4.0
4.5
3.5
Table D.4 Specified Annealed 90/10 Copper-nickel Room Temperature Mechanical Properties
Minimum tensile
strength
(MPa)
Minimum 0.2%
proof stress
(MPa)
Minimum elongation
on 5.65S0 gauge
length (%)
Maximum hardness
(HV)
310
110
35
95
43
Annex E
Specific Requirements for Aluminium-nickel-silicon-brass Tubes
(previously covered by Defence Standard 02-749 Part 3)
E.1 Scope
This Annex specifies the requirements for the manufacture, inspection, testing and supply of aluminiumnickel-silicon-brass tubes previously covered by Def Stan 02-749 Part 3.
E.2 Tube Classification

The tubes are placed in four classifications (see Table E.1). Class I to IV are in ascending order of pressure
rating.
E.3 Manufacture
E.3.1
Tube Production
Table E.1.
E.3.2
a)
Condition of Tubing
All tubes are to be solution treated and precipitation hardened. For guidance:
1)
Solution treatment consists of furnace heating the tubes to a temperature of 775C 25C for a
period of 15 minutes to 1 hour, followed by rapid water cooling.
2)
Precipitation hardening consists of furnace heating the tubes to a temperature of 500-525C for
a period of 1 hour, followed by cooling in still air.
E.3.3
Supply Requirements
E.4 Specific Tests

E.4.1
E.4.1.1
Destructive Tests
Tests shall be made on a test sample taken from each cast and each batch of tubes in the as finished and
supplied condition.
44

E.4.1.2
Chemical Analysis
finished and supplied condition.
E.4.1.3
Mechanical Tests
a)
b)
c)
A flattening test shall be carried out as detailed in clause A.2.
d)
E.4.2

E.4.2.1
E.4.2.2
documents.
E.5 Acceptance Criteria

E.5.1
Destructive Tests
E.5.1.1
Chemical Analysis
Chemical analysis of each cast and each batch of tubes shall conform to BS EN 12449- CW700R.
NOTE
Tubing supplied in accordance with this chemical composition will have a magnetic permeability figure of
not more than 1.001.
E.5.1.2
Mechanical Tests
a)
The specified tensile tests shall conform to the values in Table E.2.
b)
The specified hardness test shall conform to the values in Table E.2.
c)
In the flattening test the tubing is to show no visible evidence of cracks or flaws.
E.5.2
a)
b)
Dimensions shall meet the requirements of Table E.1 and the tolerances of Table E.3.
c)
d)

45

e)
E.5.3
outside the thickness tolerance, without the need to record where the thickness approaches the
minimum tolerance on good or rejected tubes.
Rejection
Tubes failing to meet the requirements of clause E.5 shall be rejected.
E.6 Identification
Material description in addition to requirements of clause 11 shall be AL-NI-SI-BR Def Stan 02-878
Annex E, in addition to stating the Class of tubes.
Table E.1 Tube Sizes and Working Pressures. (* Non-preferred sizes)
Wall thickness (mm)
Tube size (mm)
Class I
Class II
Class III
Class IV
0.8
1.0
9.5*
1.0*
12
0.8
1.2
16
0.8
1.6
20
1.0
2.0
25
1.6*
30
1.5
2.5
3.0
38
1.5
3.0
4.0
50
2.0
4.0
5.0
57
2.0
4.5
6.0*
76.1
2.0*
5.5
Working
Pressure (bar)
7.5
70
207
280
Table E.2 Specified Al-Ni-Si-Brass Room Temperature Mechanical Properties
46
Minimum Tensile
Strength
(MPa)
Minimum 0.2%
Proof Stress
(MPa)
Minimum Elongation
on 5.65S0 Gauge
Length (%)
450
230
40
Hardness
(HV)
125-140

Table E.3 Permitted Tube Dimensional Tolerances
Outside diameter (mm)
Wall thickness (%)
Tube size (mm)

Max.
Min.
8.045
7.965
9.5
9.545
9.465
12
12.045
11.965
16
16.045
15.965
20
20.055
19.975
25
25.055
24.975
30
30.055
29.975
38
38.07
37.99
50
50.07
49.99
57
57.2
57.12
76.1
76.32
76.15
Plus
Minus
15
47
Annex F
Advisory Material Property Datasheets
F.1 The following data sheets outline the properties of some of the tube materials previously used for
naval fluid and gas applications and other materials in commercial use that might be considered for naval
tubes. These are for comparative and advisory purposes only, and do not constitute requirements under this
Defence Standard. These data sheets do not constitute MOD approval of the contents for design purposes.
F.2 The data contained in this Annex is based on BR 3008, Materials and Processes (Mechanical
Engineering). Chapter 1: Metals, with revisions and additional material from:
48
1)
American Society of Materials Handbooks.
2)
BS EN 10216-2, Seamless steel tubes for pressure purposes. Technical delivery conditions.
Part 2: Non-alloy and alloy steel tubes with specified elevated temperature properties.
3)
BS EN 10216-5, Seamless steel tubes for pressure purposes. Technical delivery conditions.
Part 5: Stainless steel tubes.
4)
Copper Development Association publications database.
5)
Relevant manufacturers data sheets.

Table F.1 Copper-phosphorus Deoxidised Non-arsenical
Specification(s)
Nominal
Composition, %
Annex B (formerly Defence Standard 02-837), BS EN 12449- CW024A.

Copper 99.90 min, Phosphorous 0.013-0.040.
Melting range, C
1083
Physical
Properties
Density, kg/m
8940
Thermal conductivity, W/mK

Electrical resistivity,
ohm.m
Coefficient of linear expansion,
strain/K
Specific heat, J/kg K
339
386
Magnetic permeability,
Less than 1.0001
Mechanical Properties at Room Temperature

Condition
Fatigue Data
Impact Test
Data
Creep
Properties
0.017
17
Range 20-200C
Tube, annealed
(condition R220)
110 max.
200
40
Tube, 1/2 hard

(condition R250)
150
250
20
Tube, full hard

(condition R360)
320
360
3
154
40-65
117
44
0.33
76
168
70-100
117
44
0.33
110
110 min.
117
44
0.33
Izod impact value, Joules
Condition
Temperature, C
Stress, MPa
Rod, 3.2mm diameter,

annealed (32m grain size)
204
204
204
204
14.1
21.0
34.5
55.5
Creep rate, %
per 1000 hours
0.0039
0.0185
0.051
0.120
Rod, 3.2mm diameter, coldworked 84%
204
204
204
204
24.5
34.8
62.4
103.4
0.0152
0.038
0.224
2.70
0.2% Proof stress, MPa (min)

Tensile strength, MPa (min)
Elongation, % on gauge
length = 5.65 So (min)
Reduction of area, %
Shear strength, MPa
Vickers hardness
Modulus of elasticity, GPa
Modulus of rigidity, GPa
Poissons ratio
Rotating limit in air, +/- MPa,
1x107 cycles
49

Table F.1 (continued)
Marine corrosion data (full

immersion)
Joining Methods
Fabricating Properties and

Heat Treatment
Typical Uses
Remarks
50
Free corrosion potential, VSCE
-0.21
Corrosion rate, mm/year
0.075
Crevice corrosion, mm/year
0.15-0.30
Galvanic corrosion
Compatible with most copper

based alloys
Form of galvanic attack
Pitting
Impingement resistance, m/s
1.8
Soldering, brazing and TIG welding are excellent joining methods.

Gas welding can also produce good results but SMAW is not
recommended.
Suited to forming by hot and cold-working processes.
Hot-working temperature range of 750-950C.
A 95% cold reduction between anneals is possible. Annealing
temperature range of 250-650C.
General purpose tubes for hot and cold water services, evaporators
and heat exchangers; steam, air, water and oil lines.
Also suitable for any equipment involving heating in reducing gases
either during joining processes or in service.
This metal is not susceptible to hydrogen embrittlement.
The conductivity is relatively low on account of the high phosphorus
content.
Copper-zinc alloys should not be used for brazing where resistance
to seawater corrosion is a requirement.

Table F.2 70/30 Copper-nickel
Specification(s)
Nominal
Composition, %
Physical
Properties
Annex C (formerly Def Stan 02-780 Part 3), BS EN 12449- CuNi30Mn1Fe CW354H, ASTM
B111 C71500
Nickel 30.0-32.0, Manganese 0.5-1.5, Iron 0.6 -1.0, Total impurities 0.30, remainder
Copper.
Melting range, C
1170 - 1240
Density, kg/m3
8950

ohm.m
strain/K
29.3
377
1.0006

Condition
Fatigue Data
Impact Test
Data

Elongation, % on gauge length
= 5.65 So (min)
Shear strength, MPa
Vickers hardness
Poissons ratio
Rotating limit in air, +/-MPa,
1x107 cycles
0.37
16
Tube, classes 4
and 7
(annealed)
140
400
35
Range 20-300C
Tube, classes 5
and 8 (hard)
450
480
16
38
308
110 max.
152
57
0.33
142
Condition
Temperature, C
Stress, MPa
Rod, 3mm diameter, annealed
149
149
204
260
260
260
260
260
260
260
260
260
260
138
196
109
71
107
145
182
209
69
145
282
339
407
Creep
Properties:
Rod, 3mm diameter, 84% cold
worked
353
150 min.
Creep rate, % per

1000 hours
0.0004
0.0010
0.0002
0.0005
0.0009
0.0037
0.0053
0.0083
0.0011
0.0016
0.0024
0.0030
0.0120
51


immersion)
-0.18
<0.025
0.025-0.13
Galvanic corrosion

Joining Methods

Heat Treatment
Typical Uses
Remarks
52
Cathodic to most copper alloys

and therefore tends to accelerate
corrosion of copper alloys
Pitting; sometimes dealloying,
particularly at mildly elevated
temperatures
4.6
May be soft soldered, silver soldered and brazed.

Welding with gas welding, SMAW and GMAW processes is
practicable.
May be hot-worked in region 925-1050C. No forging to be carried
out below 850C.
Cold worked by forming and bending. Anneal at 650-815C.
Avoid sulphurous atmospheres.
Alloy has limited formability in range 600-925C, particularly at low
strain rates.
Tubes for heavy duty condensers, feedwater heaters and
evaporators, including desalination plant.
Iron and manganese are added to improve corrosion resistance in
high velocity waters, including polluted seawater.
The alloy is insensitive to stress corrosion.
Alloy has tendency to suffer hot spot corrosion' at locally heated
areas.

Table F.3 90/10 Copper-nickel
Specification(s)
Annex D (formerly Def Stan 02-779 Part 3), BS EN 12449- CuNi10Fe1Mn Alloy CW352H,
ASTM B111 C70600
Nominal
Composition, %
Nickel 10.0-11.0, Iron 1.0-2.0, Manganese 0.5-1.0, remainder Copper.

Melting range, C
3
Physical
Properties
Density, kg/m
8940

ohm.m
strain/K
50.2
377
1.39 annealed, 1.01 hard rolled

Condition
= 5.65 So (min)
Shear strength, MPa
Vickers hardness
Poissons ratio
Fatigue Data
1x107 cycles
Impact Test
Data
Creep
Properties
1100-1145
0.19
17
Range 20-300C
Tube, annealed
110
310
35
277
95 max
135
50
0.35
92, cold worked 25%
Condition
Temperature, C
Stress, MPa
Rod, 3mm diameter, annealed
149
149
204
204
204
204
260
260
260
102
174
63
98
132
151
63
96
126
Creep rate, %
per 1000 hours
0.0001
0.0002
0.0001
0.0007
0.0020
0.0028
0.0006
0.0017
0.0038
53


immersion)
Joining Methods

Heat Treatment
Typical Uses
Remarks
54
-0.20
<0.025
0.025-0.13
Galvanic corrosion
Slightly cathodic to most copper

alloys
Pitting
3.7
May be soft soldered, silver soldered and brazed.

Welding with SMAW and GMAW processes are practicable. Gas
welding is not recommended.
Hot-worked in range 850-950C.
Excellent cold formability characteristics with cold reduction between
annealing limited to 80%.
Annealing temperature range of 700-800C. Avoid sulphurous
atmospheres.
Used in tube form for condensers, evaporators and heat
exchangers; also tubes carrying seawater for fire mains, cooling
water circuits and sanitary services.
Iron and manganese are added to improve corrosion resistance in
high velocity waters, including seawater.
The alloy is insensitive to stress corrosion.

Table F.4 Aluminium-nickel-silicon-brass
Specification(s)
Nominal
Composition, %
Physical
Properties
Annex E (previously Def Stan 02-749 part 3); BS EN 12449 - CuZn13Al1Ni1Si1 CW700R
Copper 81.00-86.00, Aluminium 0.70-1.20, Nickel 0.80-1.40, Silicon 0.80-1.30, remainder
Zinc.
Melting range, C
1008
3
Density, kg/m
8530
77
0.11
ohm.m
19
Range 20-200C
strain/K

Condition
Fatigue Data
Impact Test
Data
Creep
Properties

= 5.65 So (min)
Shear strength, MPa
Vickers hardness
Poissons ratio
1x107 cycles
1.001
Tube, heat
treated
230
450
40
253
125-140
116
44
0.33
108
42
Condition
Temperature, C
Stress, MPa
Creep rate,
% per 1000
hours
55


immersion)
Joining Methods

Heat Treatment
Typical Uses
Remarks
56
-0.22

<0.05
0.18
Galvanic corrosion
compatible with most copper

based alloys
pitting
1.6
Welding by SMAW, GMAW and TIG processes is practicable with

the appropriate filler rods.
Brazing is the recommended method of joining.
The forging temperature range is 750-780C and the annealing
range is 600-750C.
The alloy is suited to forming by most cold-working processes; alloy
tubes should not be heated prior to bending.
Heat treatment (solution treatment and precipitation hardening) is
performed in accordance with the requirements of Annex F.
Used for high pressure hydraulic or gas systems on land and at sea.
Also on low pressure systems such as gas and steam turbine
lubrication lines where clean systems and fatigue resistance are
required.
Low magnetic permeability applications.
If very tight bends have been made or if the tube is going to be
subjected to considerable vibration, it is recommended that stress
relieving is performed by heating to 300C for one hour followed by
gradual cooling.
Not recommended for seawater systems.
Some documentation refers to this material by a manufacturers
trade name Tungum.

Table F.5 Carbon, Carbon-manganese and Chromium-molybdenum Steels
Specification(s)
Nominal
Composition, %
Physical
Properties
Def Stan 02-864, BS EN 10216-2 grades P235GH, P265GH, 20MnNb6 and 13CrMo4-5.
P235GH (Carbon steel): Carbon 0.16 max, Silicon 0.35 max, Manganese 1.2 max,
Phosphorus 0.025 max, Sulphur 0.020 max, Chromium 0.3 max, Nickel 0.3 max.
P265GH (Carbon-Manganese steel): Carbon 0.20 max, Silicon 0.4 max, Manganese 1.4
max, Phosphorus 0.025 max, Sulphur 0.020 max, Chromium 0.3 max, Nickel 0.3 max.
20MnNb6 (Carbon-Manganese steel): Carbon 0.22 max, Silicon 0.15-0.35, Manganese
1.0-1.5, Phosphorus 0.025 max, Sulphur 0.020 max, Niobium 0.015-0.10.
13CrMo4-5 (Chromium-Molybdenum steel): Carbon 0.10-0.17, Silicon 0.35 max,
Manganese 0.4-0.7, Phosphorus 0.025 max, Sulphur 0.020 max, Chromium 0.70-1.15,
Molybdenum 0.40-0.60, Nickel 0.3 max.
Melting range, C
Density, kg/m3
7850

ohm.m
strain/K
42.7-46.1
477-482
Ferromagnetic

Condition
Normalised
Yield strength (dependant on
thickness, to 60mm), MPa (min)
Elongation (longitudinal), % on
gauge length = 5.65 So (min)
Shear strength, MPa
Vickers hardness
Poissons ratio
Fatigue Data
1x107 cycles
Impact Test
Data
Elevated
temperature
properties
0.20-0.23
12.0-12.4
Range 20-100C
P235GH
215-235
P265GH
245-265
20MnNb6
335-355
13CrMo4-5
280-290
360-500
25
410-570
23
500-650
22
440-590
22
205-212 all grades

80-83 all grades
0.27-0.28 all grades
Charpy impact value, Joules
Condition
0.2% Proof Stress, MPa, at temperature C

100
200
300
400
450
500
P235GH
198
170
132
112
108
P265GH
226
192
154
134
128
20MnNb6
312
264
219
186
174
13CrMo4-5
264
245
192
174
168
166
Normalised
57


immersion)
Joining Methods

Heat Treatment
Typical Uses
Remarks
58
about -0.69
0.125-0.25
0.38-0.75 - pitting
Galvanic corrosion
Protected by zinc and aluminium

alloys
Pitting
1.2
Readily welded using gas, GMAW and TIG processes. SMAW is

also practicable although preheating and post-heating may be
required.
P235GH and P265GH supplied normalized at 880-940C, 20MnNb6
normalized at 900-960C, and 13CrMo4-5 normalized at 900-960C
and tempered at 640-720C.
Some bending can be carried out during fabrication.
Pipes and tubes for steam system pipework (P235GH and P265GH
for temperatures up to 400C and 13CrMo4-5 for temperatures of
400-500C).
Pipes and tubes for high pressure hydraulic system pipework
(20MnNb6).
Pitting corrosion can occur from condensed steam system fluids.
Outside of the pipework should be protected from corrosion.
These materials have specified elevated temperature properties.

Table F.6 18% Chromium 10% Nickel Austenitic Stainless Steel
Specification(s)
BS EN 10216-5 X5CrNi18-10 EN No. 1.4301 (formerly BS 970: 304S31). ASTM A269

S30400.
Nominal
Composition, %
Carbon 0.07 max, Silicon 1.0 max, Manganese 2.0 max, Phosphorus 0.04 max, Sulphur 0.015
max, Nitrogen 0.11 max, Chromium 17.0-19.5, Nickel 8.0-10.5.
Melting range, C
3
Physical
Properties
Density, kg/m
7970

ohm.m
strain/K
16
510
Non-magnetic (1.008), unless cold worked

Condition
= 5.65 So (min)
Shear strength, MPa
Vickers hardness
Poissons ratio
Fatigue Data
1x107 cycles
Impact Test
Data
Stress rupture
values
1400-1425
0.72
17.2
Range 20-100C
Annealed tube
195
500-700
40
200
100 min, at room temperature
Rupture time, hours
Estimated average stress for rupture, MPa, at a

temperature, C, of:
500
550
600
650
700
750
250
191
132
87
55
34
192
140
89
58
28
15
176
125
78
43
22
10 000
100 000
200 000
59


immersion)
60
-0.08
Less than 0.025
Up to 2.0 - pitting
Pitting Resistance Equivalent

Number (PREN)
18
Galvanic corrosion
Protected by aluminium alloys,

mild and low alloy steels.
Pitting
Greater than 9
Joining Methods
May be soft soldered and silver soldered with appropriate fluxes.

SMAW, GMAW and TIG processes satisfactory.

Heat Treatment
Suited to hot and cold forming operations.

Soften by rapid cooling from 1000-1100C.
Typical Uses
Applications involving moderately corrosive service.
Remarks
Good corrosion resistance, weldable.

Approximate maximum service temperature of 800C.

Table F.7 18% Chromium 10% Nickel Titanium Austenitic Stainless Steel
Specification(s)
BS EN 10216-5 X6CrNiTi18-10 EN No. 1.4541 (formerly BS 970:321S31). ASTM A269

S32100.
Nominal
Composition, %
max, Chromium 17.0-19.0, Nickel 9.0-12.0, Titanium: 5 x %carbon up to 0.7 max.
Melting range, C
3
Physical
Properties
Density, kg/m
7970

ohm.m
strain/K
14.3
Impact Test
Data
Stress rupture
values
0.73
16.6
Range 20-200C
510

Condition
Fatigue Data
1400-1425

= 5.65 So (min)
Shear strength, MPa
Vickers hardness
Poissons ratio
1x107 cycles
Annealed cold
finish tube
200
500-730
35
Annealed hot
finish tube
180
460-680
35
200
200
Rupture time, hours
10 000
100 000

temperature, C, of:
550
600
650
700
750
800
186
135
88
49
31
20
142
83
49
25
14
8
Elevated temperature
properties
Temperature, C
1% proof stress, MPa
300
158
400
148
500
140
600
135
61


immersion)
Joining Methods

Heat Treatment
Typical Uses
Remarks
62
-0.08
Less than 0.025
Up to 2.0 - pitting

Number (PREN)
18
Galvanic corrosion

Pitting
Greater than 9

No heat treatment required after welding unless for purposes of
stress relief.
Suited to forming by hot and cold-working.
Normally supplied in heat treated condition which consists of a
solution treatment achieved by heating the tubes uniformly to 10201120C then cooling rapidly in air or water.
For corrosion resistant boiler and superheater tubes.
This alloy is weldable and resistant to sensitization.
Good corrosion and oxidation resistance.
Approximate maximum service temperature 800C.

Table F.8 18% Chromium 10% Nickel Niobium Austenitic Stainless Steel
Specification(s)
BS EN 10216-5 X6CrNiNb18-10 EN No. 1.4550 (formerly BS 970:347S31). ASTM A269

S34700.
Nominal
Composition, %
max, Chromium 17.0-19.0, Nickel 9.0-12.0, Niobium: 10 x %carbon up to 1.0 max.
Melting range, C
3
Physical
Properties
Density, kg/m
7970

ohm.m
strain/K
14.3
Stress rupture
values
Elevated
temperature
properties
0.73
16.6
Range 20-200C
510

Condition
= 5.65 So (min)
Shear strength, MPa
Vickers hardness
Poissons ratio
Fatigue Data
1x107 cycles
Impact Test
Data
1400-1425
Annealed tube
205
510-740
35
200
Rupture time, hours
10 000
100 000
200 000
250 000

temperature, C, of:
550
580
600
620
650
670
237
192
166
142
112
96
172
135
115
97
74
61
156
122
102
86
64
51
86
66
136
Temperature, C
1% proof stress, MPa
300
172
400
159
500
155
700
71
600
151
63


immersion)
Joining Methods

Heat Treatment
Typical Uses
Remarks
64
-0.08
Less than 0.025
Up to 2.0 - pitting

Number (PREN)
18
Galvanic corrosion

Pitting
Greater than 9

No heat treatment required after welding unless for purposes of
stress relief.
Suited to hot and cold forming operations. Machinability poor.
Drawability very good.
Hot-working range 1100-1150C (start), 900C (finish).
Normally supplied in heat treated condition which consists of a
solution treatment achieved by heating the tubes uniformly to 10201120C and then cooling rapidly in air or water.
For corrosion resistant boiler and superheater tubes.
This alloy is weldable and resistant to sensitization. Good corrosion
and oxidation resistance.
Approximate maximum service temperature 800C.

Table F.9 18% Chromium 12% Nickel 2% Molybdenum Austenitic Stainless Steel
Specification(s)
BS EN 10216-5 X2CrNiMo18-10 EN No. 1.4404 (formerly BS 970: 316S13). ASTM A269

S31603.
Nominal
Composition, %
max, Nitrogen 0.11 max, Chromium 16.5-18.5, Nickel 10.0-13.0, Molybdenum 2.0-2.5.
Melting range, C
3
Physical
Properties
Density, kg/m
7970

ohm.m
strain/K
14.3
520
Non-magnetic (1.008).

Condition
= 5.65 So (min)
Shear strength, MPa
Vickers hardness
Poissons ratio
Fatigue Data
1x107 cycles
Impact Test
Data
Creep
Properties
1375-1400
0.76
17.2
Range 20-200C
Annealed tube
205
510-740
35
200
Condition
Temperature, C
Stress, MPa
Bar softened
535
595
650
705
760
168
145
100
63
43
Creep rate, %
per 1000 hours
0.1
0.1
0.1
0.1
0.1
65


immersion)
Joining Methods
Heat Treatment
Typical Uses
Remarks
66
-0.08
Less than 0.025
Up to 1.5-1.75 - pitting

Number (PREN)
25
Galvanic corrosion

Pitting
Greater than 9

Suited to hot and cold forming operations.
Solution treat by rapid cooling from 1020-1120C.
Corrosion resistant tubing, but unreliable in seawater contact.
Good corrosion resistance, weldable.
Approximate maximum service temperature of 800C.

Table F.10 20% Chromium 18% Nickel 6% Molybdenum Super Austenitic Stainless Steel
Specification(s)
BS EN 10216-5 X1CrNiMoCuN20-18-7, EN No. 1.4547. ASTM A269 S31254.
Nominal
Composition, %
max, Nitrogen 0.18-0.25, Chromium 19.5-20.5, Nickel 17.5-18.5, Molybdenum 6.0-7.0,
Copper 0.5-1.0.
Melting range, C
3
Physical
Properties
Density, kg/m
8000

ohm.m
strain/K
13.5
500
Non-magnetic (1.01).

Condition
= 5.65 So (min)
Shear strength, MPa
Vickers hardness
Poissons ratio
Fatigue Data
1x107 cycles
Impact Test
Data
Creep
Properties
1325-1400
0.85
16.5
Range 20-100C
Annealed tube
300
650-850
35
195
77.2
Condition
Temperature, C
Stress, MPa
Creep rate, %
per 1000 hours
67


immersion)
Joining Methods

Heat Treatment
Typical Uses
Remarks
68
-0.08
Less than 0.01
<0.01

Number (PREN)
42
Galvanic corrosion

mild and low alloy steels and
copper alloys.
Pitting
Greater than 9

No heat treatment required after welding except for purposes of
stress relief.
Good cold-working properties.
May be hot-worked in the temperature range 1000-1150C.
Solution anneal after hot-working by rapid cooling from 11401200C.
Corrosion resistant duties.
Used for equipment in contact with seawater such as heat
exchangers, condensers, cooling water pipes and similar
components, even in cases where stagnant conditions can occur.
Better resistance to pitting and crevice corrosion than conventional
stainless steels.
May be referred to by one manufacturers trade name 254SMO.

Table F.11 22% Chromium 5% Nickel 3% Molybdenum Duplex Stainless Steel
Specification(s)
Nominal
Composition, %
BS EN 10216-5 X2CrNiMoN22-5-3, EN No. 1.4462. ASTM A789 S31803.

max, Nitrogen 0.11-0.22, Chromium 21.0-23.0, Nickel 4.5-6.5, Molybdenum 2.5-3.5.
Melting range, C
3
Physical
Properties
Density, kg/m
7805

ohm.m
strain/K
19
450
Ferro-magnetic.

Condition
= 5.65 So (min)
Shear strength, MPa
Vickers hardness
Poissons ratio
Fatigue Data
1x107 cycles
Impact Test
Data
Creep
Properties
1385-1445
0.85
13.7
Range 20-100C
Annealed tube
450
640-880
22
200
Condition
Temperature, C
Stress, MPa
Creep rate, %
per 1000 hours
69


immersion)
Joining Methods

Heat Treatment
Typical Uses
Remarks
70
-0.05
Less than 0.01
0.25-0.5 - pitting

Number (PREN)
34
Galvanic corrosion

copper alloys.
Pitting
Greater than 9

Heat input should be kept low, and no pre- or post heat used.
Nitrogen added to shielding gas can be beneficial in maintaining the
duplex phase balance.
Good cold-working properties.
Solution anneal after hot-working by rapid cooling from 10201100C.
Corrosion resistant duties requiring higher strength.
Reverse osmosis plant pipework.
Better resistance to pitting and crevice corrosion than conventional
stainless steels, but not immune to corrosion in seawater.

Table F.12 25% Chromium 7% Nickel 3.5% Molybdenum Tungsten Super Duplex Stainless Steel
Specification(s)
BS EN 10216-5 X2CrNiMoCuWN25-7-4, EN No 1.4501. ASTM A789 S32760.
Nominal
Composition, %
max, Nitrogen 0.2-0.3, Chromium 24.0-26.0, Nickel 6.0-8.0, Molybdenum 3.0-4.0, Copper 0.5-1.0,
Tungsten 0.5-1.0.
Melting range, C
3
Physical
Properties
1430-1480
Density, kg/m
7840

ohm.m
strain/K
12.9
482
Ferro-magnetic: 29

Condition
= 5.65 So (min)
Shear strength, MPa
Vickers hardness
Poissons ratio
Fatigue Data
1x107 cycles
0.85
12.8
Range 20-100C
Annealed tube
550
800-1000
20
211-285
190
74
0.32
430
Impact Test
Data

70 at -46C
Elevated
temperature
properties
Temperature, C
0.2% proof stress, MPa
Tensile strength, MPa
100
470
700
200
430
670
250
400
650
71


immersion)
Joining Methods

Heat Treatment
Typical Uses
Remarks
72
+0.1-0.3
<0.01
<0.01

Number (PREN)
41
Galvanic corrosion

copper alloys.
Pitting or general corrosion
Greater than 40
SMAW, GMAW and TIG processes practicable.

Material should be in the solution treated condition before welding.
Pre-heat not required.
Matched consumable welded components should be solution treated
and quenched after welding.
Post-weld heat treatment not required if over-alloyed consumables
employed.
Suited to cold forming operations but because of the high proof
stresses requires more power than for ordinary stainless steels.
May be hot-worked in the range 1100-1280C. Avoid hot-working
below 1050C otherwise cracking may occur.
Solution treated at 1100-1120C and water quenched after hot
working.
High strength components where good resistance to crevice
corrosion, wear, erosion and cavitation is required.
Mainly used offshore for components in seawater piping, pumps,
valves, shafts, and seals.
Alloy has higher strength than austenitic stainless steels.
Good resistance to pitting, crevice corrosion and stress corrosion.
For reasons of microstructural stability, not to be used above 300C.
May be referred to by one manufacturers trade name Zeron 100.

Table F.13 Nickel-chromium-molybdenum-niobium Alloy 625
Specification(s)
Nominal
Composition, %
Physical
Properties
BS 3074- NA21. ASTM B444 N06625

Chromium 20.0-23.0, Iron 5.0 max, Molybdenum 8.0-10.0, Niobium+Tantalum 3.15-4.15,
Carbon 0.10 max, Manganese 0.50 max, Silicon 0.50 max, Phosphorus 0.015 max,
Sulphur 0.015 max, Aluminium 0.40 max, Titanium 0.40 max, Cobalt 1.0 max, remainder
Nickel.
Melting range, C
1290-1350
Density, kg/m3
8440

ohm.m
strain/K
9.8
410
1.0006

Condition
Fatigue Data
Impact Test
Data

= 5.65 So (min)
Shear strength, MPa
Vickers hardness
Poissons ratio
1x107 cycles
12.8
Range 20-100C
Tube, cold
worked and
annealed
415
830
30
208
80
0.30
610 (330 in seawater)
Condition
Temperature, C
Stress, MPa
Annealed
650
650
760
815
88
182
30
10
Condition
Temperature, C
0.2 % Proof
Stress, MPa
Annealed
200
300
400
500
340
330
330
315
Creep
Properties
Elevated
temperature
properties
1.29
Creep rate, %
per 1000 hours
0.01
0.1
0.1
0.1
73


immersion)
Joining Methods

Heat Treatment
Typical Uses
Remarks
74
-0.2
0.003
Nil
Galvanic corrosion

copper alloys
Pitting
Greater than 45.8
Alloy can be welded using SMAW, GMAW and TIG welding

processes.
The alloy can be readily brazed.
Used as a weld overlay.
Alloy can be cold formed by standard processes.
It can also be fabricated by hot forming providing adequately
powerful equipment is used. Hot-work in range 925-1175C.
Anneal 930-1040C.
To guard against duplex grain structure, the work should be given
uniform reductions.
Mooring wire ropes/cables, propeller blades, turbine exhaust ducts,
underwater sheathing, steam line bellows, springs, seals, pump
components, pump shafts, canning, fasteners and seawater cooled
plate heat exchangers.
Also used for furnace parts at temperatures up to 1100C.
Used as a weld overlay for tailshafts, stabiliser stocks and stern tube
liners.
The high nickel content provides immunity from chloride ion stress
corrosion cracking.
May be referred to by one manufacturers trade name Inconel 625.

Table F.14 Nickel-copper Alloy 400
Specification(s)
Nominal
Composition, %
Physical
Properties
BS3074- NA13. ASTM B165 N04400

Nickel 63.0 min, Copper 28.0-34.0, Iron 2.5 max, Carbon 0.3 max, Silicon 0.5 max,
Manganese 2.0 max, Sulphur 0.024 max.
Melting range, C
1300-1350
Density, kg/m3
8830

ohm.m
strain/K
21.7
423
3.20

Condition
Fatigue Data
Impact Test
Data

= 5.65 So (min)
Shear strength, MPa
Vickers hardness
Poissons ratio
1x107 cycles
13.9
Range 20-100C
Cold worked
and annealed
195
480
35
60
448
200
179
65
0.32
308 (146 in brackish water)
110
Condition
Temperature, C
Stress, MPa
Bar- hot or cold rolled and

annealed
400
400
430
430
480
480
540
540
Temperature, C
139
209
108
169
54
108
23
62
0.2 % Proof
Stress, MPa
200
400
500
135
130
125
Creep
Properties
Elevated
temperature
properties
0.51
Condition
Annealed
Creep rate, % per

1000 hours
0.01
0.1
0.01
0.1
0.01
0.1
0.01
0.1
75


immersion)
Joining Methods

Heat Treatment
Typical Uses
Remarks
76
-0.12
<0.025
0.5 - pitting
Galvanic corrosion

low alloy steels and copper alloys
Pitting
Greater than 9.1
Suitable for soft soldering, silver soldering or brazing with

phosphorus free filler but latter not advised in corrosive environment.
SMAW, GMAW and gas welding processes practicable with
appropriate fillers.
Used as a weld cladding material.
May be hot-worked in range 925-1180C but is hot-short in range
650-925C.
Alloy may be readily cold-worked. Anneal 870-980C.
Avoid heating in sulphur bearing atmospheres and contamination
during processing with sulphur bearing cutting fluids.
Fasteners (nuts and washers), bellows, seawater pump shafts, valve
spindles and seals, pump sleeves, wear rings, propeller shafting,
and tubes for steam coils in calorifiers.
Also used as a cladding material.
Not suitable for use in sulphur bearing atmospheres above 370C.
Alloy had a good reputation for seawater corrosion resistance but
this was in part due to galvanic protection by copper alloys to which
it was frequently coupled.
May be referred to by one manufacturer trade name Monel 400.

Table F.15 Titanium Alloy, Commercial Purity
Specification(s)
Nominal
Composition, %
Physical
Properties
NES 310 (obsolete). ASTM B338 Grades 1 and 2

Titanium balance, Oxygen 0.18 max (dependant on grade), Nitrogen 0.03 max, Carbon
0.1 max, Composition, % Iron 0.2 max, Hydrogen 0.008, other elements in total 0.1-0.3
max
Melting range, C
1660
Density, kg/m3
4510

ohm.m
strain/K
16
52.8
1.0002

Condition
Fatigue Data
Impact Test
Data
Creep
Properties
0.2% Proof stress, MPa

= 5.65 So (min)
Shear strength, MPa
Vickers hardness
Poissons ratio
1x107 cycles
0.50
7.6
Tube, annealed
(NES 310)
260-370
440-530
25
Range 20-100C
ASTM B338
Grade1
170-310
240
24
ASTM B338
Grade2
275-450
345
20
Creep rate, %
per 1000 hours
0.1
0.1
0.1
0.1
0.1
0.1
360
170
105
38
0.34
232
61
Condition
Temperature, C
Stress, MPa
Annealed
20
100
150
200
250
300
288
179
140
113
96
87
77


immersion)
-0.05
Less than 0.0003
Nil, unless >70C
Galvanic corrosion

Joining Methods

Heat Treatment
Typical Uses
Remarks
78
Protected by coupling to low alloy

/ mild steels, aluminium and
copper alloys, and most stainless
steels and nickel alloys
Nil, but excessive cathodic
protection can cause hydride
formation.
Greater than 9.15
Titanium can be joined by GMAW, TIG, resistance, flash-butt,

pressure or friction welding processes.
Techniques are governed by the affinity of the metal for atmospheric
gases; equipment may need modification to protect the under
surface as well as the top surface of a weld run.
Limited ability for pressing, stretch forming and spinning.
Anneal at 650-700C. Stress relief is complete after half an hour at
300-500C.
Titanium can be contaminated by atmospheres containing free
hydrogen or hydrogen compounds.
Tubular and plate type heat exchangers for condensers, evaporators
etc. in marine vessels and water purification plants, for example
steam drain coolers, and main condenser U-tubes.
Also used for other specialist components in contact with seawater,
fasteners and in diesel exhaust systems.
Has very good marine corrosion resistance and the use of this metal
should be considered for applications where the cost of fabrication is
large in relation to the amount of material used.

Table F.16 Aluminium-magnesium-manganese Alloy
Specification(s)
Nominal
Composition, %
Def Stan 02-831 (superseded), BS EN 755, Alloy EN AW-5083. This material

supersedes BS 1470 N8.
Magnesium 4.0-4.9, Manganese 0.40-1.0, Chromium 0.05-0.25, Silicon 0.40 max, Iron
0.40 max, Copper 0.10 max, Zinc 0.25 max, Titanium 0.15 max remainder Aluminium.
Melting range, C
3
Physical
Properties
Density, kg/m
2670

ohm.m
strain/K
109
Condition
Fatigue Data
Impact Test
Data
580-645

= 5.65 So (min)
Shear strength, MPa
Vickers hardness
Poissons ratio
1x107 cycles
0.06
24.5
Annealed tube
(O condition)
125
275
11-16
155
75
71
26
0.33
124
Temperature, C
Creep
Properties
Range 20-100C
Stress, MPa
Creep rate, %
per 1000 hours
79


immersion)
-0.75
0.05, greater if cold worked

Galvanic corrosion
Joining Methods

Heat Treatment
Typical Uses
Remarks
80
0.15 Prevented by use of

inhibited jointing compounds
Corroded by coupling to steels
and copper alloys
Pitting and intergranular
corrosion
4.6
This alloy can be easily welded by the normal GMAW and TIG
processes.
Resistance, spot and seam methods should also give excellent
results.
May be formed, drawn or spun by normal cold-working processes
but this may adversely affect corrosion resistance when subjected to
service temperatures in range 50-100C.
During severe forming operations, this alloy will need interstage
annealing.
Salt water services and marine applications, cryogenics and welded
pressure vessels.
After welding, the strength of the alloy is reduced to that of the
annealed (O) temper in the heat affected zone.
Corrosion properties may be improved by anodizing and sealing.
Maximum service temperature 100C.

Table F.17 Aluminium-2% magnesium alloy
Specification(s)
Nominal
Composition, %
Def Stan 02-831 (superseded), BS EN 755, Alloy EN AW-5251. This material

supersedes BS 1470 N4.
Magnesium 1.7-2.4, Manganese 0.1-0.5, Silicon 0.40 max, Iron 0.50 max, Copper 0.15
max, Zinc 0.15 max, Chromium 0.15 max, Titanium 0.15 max, remainder Aluminium.
Melting range, C
3
Physical
Properties
Density, kg/m
2690

ohm.m
strain/K
155
963

Condition
Fatigue Data
Impact Test
Data
Creep
Properties
595-650

= 5.65 So (min)
Shear strength, MPa
Vickers hardness
Poissons ratio
1x107 cycles
Rolled plate
0.05
24
Range 20-100C
Def Stan 02-831

Extruded tube
(F condition)
60
170
14
70
26.5
0.32
Temperature, C
Stress, MPa
65
65
150
150
150
205
205
205
62
123
38.5
54
77
15.4
23
31
Creep rate, %
per 1000 hours
0.013
1.20
0.015
0.083
5.00
0.021
0.092
0.60
81


immersion)
-0.75
0.03
Rarely experienced
Galvanic corrosion
Joining Methods

Heat Treatment
Typical Uses
Remarks
82
Corroded by coupling to steels

and copper alloys
Pitting and intergranular
corrosion
4.6
Braze soldering practicable (poor corrosion resistance).

Can be welded by TIG and GMAW processes using filler containing
Magnesium or 5% Silicon.
Resistance welding processes practicable.
Readily cold-worked by all normal processes.
Hot-work in range 260-510C.
Anneal by heating to 345C.
For applications where good workability, corrosion resistance
combined with moderate strength are required.
Used for pipes, fuel tanks and miscellaneous marine applications.
For good service in marine environments avoid contamination by
copper corrosion products.
Corrosion properties may be improved by anodizing and sealing.
Inside Rear Cover
Crown Copyright 2011
Copying Only as Agreed with DStan
Defence Standards are published by and obtainable from:

Defence Equipment and Support
UK Defence Standardization
Kentigern House
65 Brown Street
GLASGOW
G2 8EX
DStan Helpdesk
Tel: +44 (0) 141 224 2531/2

Fax: +44 (0) 141 224 2503
Internet e-mail: enquiries@dstan.mod.uk
File Reference
The DStan file reference relating to work on this standard is D/DStan/69/2/878.
Contract Requirements
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application and for complying with contractual and statutory requirements. Compliance with a Defence
Standard does not in itself confer immunity from legal obligations.
Revision of Defence Standards
Defence Standards are revised as necessary by an up issue or amendment. It is important that users of
Defence Standards should ascertain that they are in possession of the latest issue or amendment.
Information on all Defence Standards can be found on the DStan Website www.dstan.mod.uk, updated
weekly and supplemented regularly by Standards in Defence News (SID News). Any person who, when
making use of a Defence Standard encounters an inaccuracy or ambiguity is requested to notify UK
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with any standards work.

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Ministry of Defence

Defence Standard 02-878

Non-Ferrous Tubes and Pipes

DEF STAN 02-878 Issue 1

Normative References ...........................................................................................................................1

Terms and Definitions............................................................................................................................3

Design Requirements ............................................................................................................................4

Information to be Supplied by the Purchaser ...................................................................................13

DEF STAN 02-878 Issue 1

Annex A Test Methods Specific to this Defence Standard ........................................................................21

DEF STAN 02-878 Issue 1

DEF STAN 02-878 Issue 1

DEF STAN 02-878 Issue 1

DEF STAN 02-878 Issue 1

Signature and Date

DEF STAN 02-878 Issue 1

The complete Defence Standard 02-878 Issue 1 comprises:

DEF STAN 02-878 Issue 1

Category 1. If not applied, may have a Critical effect on the following:

Category 2. If not applied, may have a Significant effect on the following:

Category 3. If not applied, may have a Minor effect on the following:

British Standards Institution,

Defence Equipment and Support

Tender or Contract Sponsor to advise.

DEF STAN 02-878 Issue 1

DEF STAN 02-878 Issue 1

Aluminium-nickel-silicon-brass can become susceptible to stress corrosion cracking if excessively cold

DEF STAN 02-878 Issue 1

DEF STAN 02-878 Issue 1

Non-Ferrous Tubes and Pipes for use in HM Submarines and

Code for pressure piping

Nickel-copper alloy (UNS N04400) seamless pipe and tube

Evaluation stress-corrosion-cracking resistance of metals and alloys in a boiling

Practice for making and using C-ring stress-corrosion test specimens

Regulations for atmosphere control in submarines

Materials and processes (Mechanical Engineering).

DEF STAN 02-878 Issue 1

Admiralty pipework standards: Imperial and metric

Shock and vibration manual

Nickel and nickel alloys: seamless tube

Seamless steel tubes for pressure purposes. Technical delivery conditions

Unfired pressure vessels

Metallic industrial piping

Metallic materials - Vickers hardness test

Metallic materials. Tensile testing

Salt water piping systems in ships

Def Stan 02-329

Requirements for heat exchangers for HM Surface Ships and Submarines

Def Stan 02-719

Sea Water Systems for H M Surface Ships

Def Stan 02-729

Requirements for non-destructive examination methods

Def Stan 02-772

Welding and fabrication of pipework, machinery and engineering components for HM

Def Stan 02-781

Protection of Seawater System Pipework and Heat Exchanger Tubes in HM Surface

Def Stan 02-797

Def Stan 02-864

Carbon, Carbon-Manganese, and Chromium-Molybdenum Steel Pipes and Tubes for

Def Stan 07-247

The selection of materials on the basis of their fire characteristics

Def Stan 08-120

Requirements for determining the shock strength of equipment (Restricted)